SCHEDULE OF ITEMS - ASH POND DIVIDE BUND Sl No. Rate ... · SCHEDULE OF ITEMS - ASH POND DIVIDE BUND Sl No. Rate Amount (Rs) (Rs) I-1 EXCAVATION AND FILLING 1. ... Ordinary formwork

Project No: HD18117000Doc. No:HD18117000-VB00-00-ZEN-170001

3x660 MW Thermal Power Plant

Talwandi Sabo Power Limited

Rev: P0 (Draft)

SCHEDULE OF ITEMS - ASH POND DIVIDE BUNDSl No. Rate Amount

(Rs) (Rs) I-1 EXCAVATION AND FILLING

1.

Earthwork in excavation upto 2.5 m depth below existing ground level for foundations, trenches,pipe lines, storm water drains etc. including lifting, dressing of sides and ramming of bottom,shoring, strutting, dewatering, stacking of excavated soil dewatering with all equipment andmaterials complete as per specification, drawings and instructions of the Purchaser / Engineer,including a lead upto 500 m within plant boundary for all types of Soil, Weathered rock and Hardrock.

a) In all types of soil /Fly Ash Cu m 47,474 b) In Weathered / Soft rock Cu mc) In Hard rock Cu m

2. Disposal of all types of surplus excavated earth within/outside plant boundary etc. all complete asper specification, drawing and instructions of the Purchaser / Engineer.a) Carriage beyond initial leads of 500 m and upto 2 km within plant boundary. Cu m 1,500 b) Carriage beyond the plant boundary upto 5 km. Cu m

3.

a) Filling using either locally available suitable earth or "fly ash in layers not exceeding 225mmloose thickness (compacted to 150 mm ) including lead upto 1 km and all lifts and includingloading from stock pile, carting, unloading, filling, watering and compacting each layer etc. allcomplete as per specification, drawings and as directed by the Purchaser / Engineer.

i) Compaction to 95% of modified proctor density or 80% of relative density Cu m 62,809 ii) Compaction to 95 % standard proctor density or 70% of relative density Cu m

b) Filling/providing and laying earthen embankment using selected excavated borrowed earth(SC, CL, CI, CI-CL, ML-CL, ML or GC in layers not exceeding 225mm loose thickness(compacted to 150 mm ) including average lead up to 2.5 Km and all lifts and including cost of allmaterials, labor and all operations such as excavation, sorting, loading from stock pile, carting,unloading, filling, watering and compacting each layer, dewatering etc. all complete as perspecification, drawings and as directed by the Purchaser / Engineer.

i) Compaction to 95% of modified proctor density (heavy compaction). Cu m 95,846 ii) Compaction to 95 % standard proctor density (Standard effort). Cu miii) With CNS ( Cohesive Non- Swelling ) material as per specifications and compacting to 95% of modified proctor density

Cu m

c) Providing and filling the cut off trench and / or Central Core (if required) with impervioussoil (either natural inorganic, low to intermediate plastic fine soil (non-expansive) or prepared soilmixed with bentonite or approved equivalent (not less than 2 per cent by volume) to achieve apermeability less than 1 x 10-6 cm / sec) in layers of 250 to 300 mm loose thickness including costof all materials, machinery and labour all operations, such as excavation, sorting, transportation,loading, unloading, dozing to the required depth, breaking the clods, sectioning, watering andcompacting to the required density using rollers of 8 to 10 MT capacity with all leads notexceeding 5 km within plant area, all lifts, dewatering, desilting etc., complete as per detailedspecifications.

i) Compaction to 95% of modified proctor density (heavy compaction). Cu m 6,319 ii) Compaction to 95 % standard proctor density (Standard effort). Cu m

4.

Providing & constructing rock-toe using clean, hard and selected rubble including filling withchips and wedging for face works including all operations such as quarrying, loading,transportation, unloading, placing, packing, finishing the top and sides to required slopes includingdesilting, cost of all materials, machinery, labour etc., all complete as per specification, drawingsand instruction of the Purchaser / Engineer.

i) Aggregate Size 100 to 350 mm Cu m 3,725 ii) Aggregate Size 40 to 80 mm Cu m 2,789

5. Lowering of Ground water table by Deep Dewatering / Well point dewatering method all completeto maintain dry working condition in foundation pits till all construction and backfilling activitiesetc. are complete

Hours

I-2 FORMWORK

6.

Supplying and fixing formwork of approved quality for cast-in-situ, plain or reinforced concreteworks of any type and section (including curved surfaces) at all elevations, including labour,materials, equipment, shoring, strutting, scaffolding, staging, tieing, nailing, caulking, bolting,testing, etc., and removal of formwork and staging, design and preparation of working drawings ofscaffolding and support structures etc. all complete as per specification, drawings and instructionsof the Purchaser / Engineer.

a) For works below ground leveli) Ordinary formwork Sq m 1,000 ii) Plywood formwork Sq mb) For works above ground leveli) Ordinary formwork Sq mii) Plywood formwork. (Film Faced) Sq m

I-3 REINFORCEMENT

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Supplying and placing reinforcement, in reinforced concrete and allied works, at all levels,including transportation, cleaning, straightening, cutting, bending, binding in position withannealed wire and/or welding, Supplying concrete cover blocks, pins, separators, chairs, supportsfor reinforcement, etc., with all materials, labour, equipment, handling, transporting, testing etc.,preparation of bar bending drawings and schedules all complete as per specifications, designdrawings and instructions of the Purchaser / Engineer.

a) For works below ground leveli) Mild Steel reinforcement MTii) High yield strength deformed bars (Fe 415 / Fe 500) / TMT bars MT 5 b) For works above ground leveli) Mild Steel reinforcement MTii) High yield strength deformed bars (Fe 415 / Fe 500) / TMT bars MTc) Reinforcement for RCC panel above HDPE liner (Fe 415 / Fe 500) / TMT bars MT

Description of Items Unit Qty.




Rev: P0 (Draft)


(Rs) (Rs) Description of Items Unit Qty.

I-4 CONCRETING

8

Supplying and laying Nominal Mix Plain Cement Concrete using graded aggregate at all levels forall kinds of work like mass concrete, bed blocks, lean concrete, mud mat, filling, etc. includinglabour, materials, equipment, handling, transporting, batching, curing, testing, etc. all complete asper specification, drawings and instructions of the Purchaser / Engineer but excluding shutteringwork.

a) 1:5:10 (with 40mm down size grading) Cu m NAb) 1:4:8 (with 20mm down size grading) Cu m 50 c) 1:3:6 (with 40mm nominal size graded aggregate). Cu m NAd) 1:2:4 (with 20mm down size grading) Cu m NAe) 1:1.5:3 (with 20mm down size grading) Cu m NA

9

Supplying and laying Design Mix Cement Concrete for reinforced concrete work at all levels forall kinds of work, including labour, materials, equipment, handling, transporting, batching, mixing,controlling temperature, placing, levelling, compacting, curing, testing, etc. all complete as perspecification, drawings and instructions of the Purchaser / Engineer, but excluding centering,shuttering and reinforcement work.

a) For works below ground leveli) M-20 (with 20mm nominal size graded stone aggregate). Cu m NAii) M-25 (20mm nominal size graded stone aggregate). Cu m NAiii) M-30 (Temperature controlled concrete with admixture and 20mm nominal size gradedstone aggregate).

Cu m NA

iv) M-35 (Temperature controlled concrete with admixture and 20mm nominal size gradedstone aggregate).

Cu m NA

b) For works above ground leveli) M-20 (with 20mm nominal size graded stone aggregate). Cu m NAii) M-25 (with 20mm nominal size graded stone aggregate). Cu m 100

I-5 BRICK MASONRY AND ALLIED WORKS NA

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a) Supplying and laying in position clay / fly ash brick masonry works with minimum crushingstrength of 75 kg/cm2 in cement-sand mortar 1:6 (1 Cement: 6 Sand) including mixing mortar,laying bricks, raking out joints, scaffolding, curing complete as per specification, drawings andinstructions of the Purchaser / Engineer.a) 230thk Cu m 1,058

I-6 PLASTERING AND ALLIED WORKS NA

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Supplying 15mm thick cement plaster in single layer on all types of concrete surface or fair side ofmasonry, for all types of work, for all elevations, including scaffolding, surface preparation,mixing, application, finishing, curing, testing etc., complete with all materials, handling labour,tools and plants, etc.all complete as per specification, drawings and instructions of the Purchaser /Engineer for the following mix proportions. :

a) Cement mortar 1:4 (1 cement : 4 sand) Sq m 3,150 b) Cement mortar 1:5 (1 cement : 5 sand) Sq mc) Cement mortar 1:6 (1 cement : 6 sand) Sq md) Cement mortar 1:4 (1 cement : 4 sand) with neat cement finish Sq m

I-7 U/S and D/S Slope Protection measures and Drains

12Providing, loading, transporting, unloading, laying all materials, labour etc., and including placing, jointing HDPE liner for upstream slope and reservoir floor as per ASTM requirements.

a) 600 micron thk. Sq m 22,617 b) 750 micron thk Sq mc) 1mm thk Sq m

13

Providing & laying 150 mm thk cushion material (below HPDE lining in embankment slope and reservoir floor), as per drawings, including cost of all materials, machinery and labour all operations such as quarrying, loading, transportation, unloading, screening, placing in the required layer using formwork, watering and compacting to the required density using vibrators with all leads and lifts etc., complete as per specifications.

- Graded natural sand (D15<=0.7mm) Cu.m- Ash / bottom ash Cu.m 22,617 - Low permeable soil as Cushion material Cu.m NA

14 a) Providing & laying sand filter of approved quality at embankment sand chimney, blanket (horizontal drain) and Rock Toe including trench cutting, screening, washing, watering, compaction, dressing, necessary trimming if any including all leads and lifts etc, all complete as per specifications.

Cu.m 4,572

15

Providing, and laying bick on edge pitching over HDPE Liner including with 100 mm thick bottom ash including supply of material, moulding, formwork, wiremesh, batching, mixing, laying, compacting, curing, handling, storing, transporting, all leads, erection without damage; filling the gaps between adjacent units with concrete or grout. (a ) Using Fly ash bricks Sq m 20744

16Providing, loading, transporting, unloading, laying all materials, labour etc., and including placing, jointing/ overlapping 1.5 mm thick non-woven geotextile filter for rock toe and draiange as per ASTM requirements.

Sq m 12586

TOTAL AMOUNT IN WORDS: ______________________________________________________________

SIGNATURE OF THE BIDDER: ______________________________________

DATE: __________________


And

(Vendor Name as mentioned on Page 1 of this service/work order)

Contract# xxxxxxxxxxxxx

__________________________________________________

CONTRACT FOR PROVISION OF [ ] SERVICES

____________________________________________________

2

THIS AGREEMENT is made on (as mentioned on page no:1 of this service order) BETWEEN (1) Talwandi Sabo Power Ltd., a company incorporated in India currently having its registered

office at Banawali,Mansa, (hereinafter referred to as the “Company”, which expression, unless the context requires otherwise, shall include its successors and permitted assignees); and

(2) (Vendor Name as mentioned on Page 1 of this service/work order a company

incorporated under the provisions of Company Act, 1956 and having its registered office at address of the vendor as mentioned on Page 1 of this order (hereinafter referred to as the “Service Provider”, which expression, unless the context requires otherwise, shall include its successors and permitted assignees).

RECITALS:

WHEREAS the Company requires the Service Provider to provide certain services and the Service Provider is engaged in the business of providing such services and has agreed to perform the Services for the Company on the terms and conditions set out in this Contract. NOW THEREFORE IT IS HEREBY AGREED as follows: 1. The Service Provider agrees to perform the Services in accordance with the terms and

conditions of this Contract and, in consideration of its due performance of the Services, the Company agrees to pay the Service Provider according to the rates, terms and conditions herein contained.

2. The Contract shall comprise the following documents:

This Agreement Schedule I: Standard Terms and Conditions Attachment 1 to Schedule I: Scope of work Attachment 2 to Schedule I: Compensation Schedule

(all hereinafter the “Agreement”).

3. In the event of any inconsistency or discrepancy between any of the documents listed above,

the Standard Terms and Conditions shall have preference over any other documents and these Standard Terms and Conditions shall apply and shall be incorporated by reference / deemed incorporated in any Purchase Order issued hereunder and shall prevail at all times between the Parties over any other terms and conditions (including any terms or conditions which Service Provider purports to apply except where the Parties by its/their authorized signatories have specifically agreed in writing to vary and override the said Standard Terms and Conditions.

4. The effective date of this Agreement shall be ****** (hereinafter the “Effective Date”) and

this Agreement shall be valid for a period of ***** from the Effective Date / up to ***** (“Term”).

5. For the purposes of Clause 8 (Payment) of Schedule I (Standard Terms and Conditions), the

address for sending invoices shall be as follows:

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Accenture *__________ Contact: Email: Attention:

6. For the purposes of Notices Clause of Schedule I (Standard Terms and Conditions), the address

for notices shall be: If to the Company: Talwandi Sabo Power Limited Limited

*__________ Attention: Email: *****************

Ph: *****************

If to the Service Provider: XXXXXXXXXXXXXXXXX

7. For the purposes of this Agreement, the Company’s representative shall be **************** & for operational matters shall be **********. The Service Provider’s representative shall be XXXXXXXXX for all matters, including contractual and operational.

IN WITNESS WHEREOF the Parties hereto have executed this Agreement on the day, month and year herein above written: Signed by………………………………………

……………………………. for and on behalf of TALWANDI SABO POWER LIMITED Witness……………………………………………………. ………………………………………..[Witness Name]

Signed by……………………………………………………. ………………………………………… for and on behalf of XXXXXXXXXXXXX Witness……………………………………………………. ……………………………………

PLEASE TICK: � WE HAVE READ THE STANDARD TERMS AND CONDITIONS ENCLOSED WITH THIS

AGREEMENT

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SCHEDULE I STANDARD TERMS AND CONDITIONS 1. DEFINITIONS 1.1 In the Agreement, the following words

and expressions shall, unless the context otherwise requires, have the following meanings: “Affiliate” shall mean with respect to any person, any other person that, directly or indirectly, controls, is controlled by or is under common control of such specified person. For the purposes of this definition, “control” means the direct or indirect beneficial ownership of more than fifty percent (50%) of the issued share capital, stock or other participating interest or the legal power to direct or cause the direction of the general management of the company, partnership or other person in question, and “controlled” shall be construed accordingly; “Agreement” shall mean the Agreement between the Company and the Service Provider to which this Schedule is attached. “Purchase Order” shall mean the document recording the specific Services to be carried out under this Agreement, from time to time. “Fees” shall mean the prices and/or rates payable by the Company in respect of the Services and/or as specified in the relevant Purchase Order.

1.2 Unless otherwise stated, any and all

references in the Agreement to Clauses are references to the Clauses of the Agreement.

1.3 The headings in the Agreement are used

for convenience only and shall not govern or affect the interpretation of the Agreement.

1.4 Words denoting the singular shall include

the plural and vice versa, where the context requires.

1.5 Except as expressly identified, any

reference to statute, statutory provision or statutory instrument shall include any

re-enactment or amendment thereof for the time being in force.

1.6 Unless expressly stated otherwise, all

references to days, weeks, months and years shall mean calendar days, weeks, months and years.

2. SCOPE OF CONTRACT 2.1 The terms and conditions of the

Agreement shall apply from the Effective Date and shall remain valid for the Term unless this Agreement is terminated earlier by the Company in accordance with Clause 10 below (Standard Terms and Conditions).

2.2 Subject to the provisions of this

Agreement, the Parties agree that upon request of the Company in terms hereof, the Service Provider shall perform the Services at such locations and for such periods as may be agreed with the Company.

2.3 From time to time, the Company may

issue a Purchase Order to the Service Provider. In such case, the terms and conditions of this Agreement shall apply to each such Purchase Order as if repeated in total.

2.4 The Service Provider shall commence the Services on the scheduled commencement date stated in the Purchase Order and shall continue such Services for the duration of the Purchase Order. Each Purchase Order is subject to agreement on a case by case basis.

3. SERVICES 3.1 The Service Provider shall perform the

Services with all due skill, care and diligence in a safe, competent and timely manner and in accordance with the requirements of the Agreement and/or the relevant Purchase Order.

3.2 Except to the extent that it may be legally

or physically impossible, the Service Provider shall comply with the Company’s

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instructions and directions in all matters relating to the Services consistent with the provisions hereunder.

3.3 The Service Provider shall agree with the

Company in the relevant Purchase Order from time to time as regards the personnel who will perform the Services and shall:

(a) only provide such personnel who

possess appropriate experience, skills and qualifications necessary for the Services to be performed in accordance with this Agreement;

(b) not remove or replace such

personnel without the prior written consent of the Company (not to be unreasonably withheld); and

(c) nominate a senior manager or

director of the Service Provider to have overall responsibility for the provision of the Services in terms of the relevant Purchase Order, which person shall attend any meetings with the Company on reasonable prior notice.

3.4 The Company shall be entitled to request

the Service Provider to replace any of its personnel providing the Services, where in the Company’s reasonable opinion such person is incapable and or unsuitable for performing the Services required by this Agreement. The Service Provider shall promptly replace such person at no additional cost to the Company.

3.5 Without prejudice to any other rights of

the Company under the Agreement or at law, if the Service Provider fails to perform the Services in accordance with the provisions of this Agreement, the Company may use alternative means to perform the Services and the Service Provider shall be liable for any additional cost incurred by the Company in using such alternate means.

4. FEES 4.1 The Company shall pay for the Services

performed in accordance with the prices as per Attachment 2 to Schedule I and/or

rates specified in the relevant Purchase Order.

4.2 In case of contingency assignments, the

agreed fees for such onetime Services shall be payable on completion of the relevant assignment as per the Purchase Order.

5. SERVICE PROVIDER’S GENERAL

OBLIGATIONS 5.1 The Service Provider shall, and the Service

Provider shall ensure that its employees and representatives shall, in performing its obligations under this Agreement, comply in all respects with all relevant laws, statutes, regulations and orders for the time being in force.

5.2 Where any of the Service Provider’s

employees or representatives is present at any of the Company’s premises for the purposes of this Agreement, the Service Provider shall at all times remain responsible for the conduct and safety of such employee or representative.

5.3 The Service Provider shall not, in

performing its obligations under this Agreement, hold itself out or permit any person to hold it out as being authorised to bind the Company in any way and will not commit any act which might reasonably create the impression that it is so authorised.

5.4 The Service Provider shall ensure that it

has in place and maintains in place for the duration of this Agreement sufficient insurance to comply with all applicable laws and to cover its potential liabilities under this Agreement and shall provide evidence of such insurances to the Company on request.

5.5 The Service Provider may not subcontract

any of its obligations under this Agreement without the prior written consent of the Company. The Service Provider shall not be relieved from any of its obligations or liabilities under the Agreement by virtue of any subcontract and the Service Provider shall be responsible for all Services, acts, defaults or omissions of its subcontractors (and its or their employees and consultants) as

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though they were the services, acts, defaults or omissions of the Service Provider.

5.6 In performing the Services, the Service

Provider shall:

(a) give preference to the purchase and use of goods manufactured, produced or supplied in India provided that such goods are available on terms equal or better than imported goods with respect to the timing of delivery, quality, quantity required, price and other terms;

(b) subject to Clause 5.5, employ Indian

subcontractors having the required skills or expertise to the maximum extent possible insofar as their services are available on comparable standards with those obtained elsewhere and at competitive prices and on competitive terms, provided that where no such sub-Contractors are available, preference shall be given to non-Indian subcontractors who utilise Indian goods to the maximum extent possible, subject to the proviso in Clause 5.6 (a) above; and

(c) subject to Clause 5.5, co-operate with

and assist Indian companies as subcontractors to enable them to develop skills and technology to service the petroleum industry.

5.7 The Service Provider shall maintain

proper and accurate records in relation to the Services and shall provide copies of the same to the Company on request. The Company (or its appointed representative) shall have the right to audit the relevant books and accounts of the Service Provider in relation to any reimbursable charges paid for by the Company under this Agreement. Such audit right shall survive for a period of 2 (two) years following the expiry or termination of the Agreement. Any incorrect payments identified by such audit shall be adjusted between the Parties as appropriate.

6. THIRD PARTY CLAIMS AND LIMITATION

OF LIABILITY

6.1 - The Service Provider shall be liable for and shall defend, indemnify and hold the Company harmless from and against any and all claims, liabilities, costs, damages and expenses (including court costs and legal fees) in connection with: (a) any claim made by any third party

(including,but not limited to, any claim made by any governmental or statutory authority) against the Company arising out of or in connection with the performance by the Service Provider of its obligations under this Agreement.

(b) any infringement (whether actual or alleged)of any patent or other intellectual property right arising out of or in connection with the performance of this Agreement by the Service Provider

6.2 Notwithstanding anything to the contrary in this Agreement, in no event shall either Party be liable to the other, whether arising under Agreement, tort (including negligence), strict liability or otherwise, for any indirect, consequential, special, punitive, exemplary or incidental loss or damages of any nature arising at any time from any cause whatsoever.

7. VARIATIONS

7.1 At any time during this Agreement, the

Company may request the Service Provider to vary, amend or otherwise alter the Services (a “Variation Request”).

7.2 Upon the receipt of a request from the

Company pursuant to Clause 7.1, the Service Provider shall, within 7 days, notify the Company of the effect of the Variation Request on the Fees and/or other terms of the relevant Order.

7.3 If following receipt of the Service

Provider’s response pursuant to Clause 7.2, the Parties are in agreement on the Variation Request and the adjustments to be made to the relevant Purchase Order, the Parties shall execute a variation order (a “Variation Order”) to reflect such agreement.

7.4 The Services shall not be varied, amended

or otherwise altered and/or the Fees shall not be adjusted until such time as a Variation Order is executed by both Parties.

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8. PAYMENT 8.1 In addition to any requirements set out in

the relevant Purchase Order, each invoice shall:

(a) be in duplicate; (b) bear the Contract Number stated on the cover sheet to the Agreement; (c) state the name, e-mail address, mobile telephone number of the Company's Representative; and (d) be accompanied by supporting evidence and itemised in accordance with the Company's requirements. Specifically, the Service Provider shall submit the following information/ documents to the Company: (i) Copy of registration certificates

under Indian tax/other laws including but not limited to Service Tax, Excise, import export code etc., as applicable.

(ii) Copy of PAN. Invoices to the Company shall be sent to

the address set out in the Agreement. Service Provider must ensure that all invoices for services performed or goods delivered are submitted to the Company within 90 days.

8.2 The Company shall make payment of a

correct invoice within 45 days of receipt to the Service Provider’s nominated bank account. Any invoice not complying with the provisions of this Agreement will be returned by the Company and the Service Provider shall submit a rectifying invoice.

8.3 The Company may dispute any amount on

an invoice and withhold the disputed amount provided that:

(a) the Company makes payment of any

undisputed portion of the invoice and notifies the Service Provider of the disputed amount within 45 days of receipt of the relevant invoice;

(b) if the dispute is resolved in favour of

the Service Provider, the Company shall pay the disputed amount within fifteen (15) days of the date of the resolution of the dispute or forty-five

(45) days of receipt of the invoice, whichever is later.

If the dispute is resolved in favour of the Company, the Service Provider shall forthwith issue a credit note for the disputed amount.

8.4 The Company shall be entitled to set-off / adjust / deduct from any invoice under this Agreement, any payment due from the Service Provider to the Company or any of its Affiliates.

9. TAXES

9.1 Definitions

For the purposes of this Clause 9:

(a) “Tax” or “Taxes” means taxes, levies, duties, fees, charges and contributions as amended from time to time and any interest or penalties thereon;

(b) “Government Authority” or “Government Authorities” means any local or national government or authority of any country, competent to levy any Tax.

9.2 Person Responsible for payment of taxes

Except as may be expressly set out in this Agreement, the Service Provider shall be responsible for:

(a) the payment of all Taxes now or

hereafter levied or imposed on the Service Provider or its subcontractors or on the personnel of the Service Provider or its subcontractors by any Government Authority in respect of any wages, salaries and other remuneration paid directly or indirectly to persons engaged or employed by the Service Provider or its subcontractors (hereinafter referred to as “Personal Income tax”);

(b) the payment of all Taxes now or hereafter levied or imposed by any Government Authority on the actual/assumed profits and gains made by the Service Provider or its subcontractors (hereinafter referred to as “Corporate Income tax”);

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(c) the payment of all Taxes now or hereafter levied or imposed by any Government Authority on the services, if any, provided to the Company by the Service Provider or its subcontractors (hereinafter referred to as “Service tax”);

(d) the payment of all Taxes now or hereafter levied or imposed by any Government Authority on the goods, if any, sold to the Company by the Service Provider or its subcontractors (hereinafter referred to as “Sales tax/VAT”);

(e) the payment of all Taxes now or hereafter levied or imposed by any Government Authority on the goods, if any, manufactured by the Service Provider or its subcontractors for sale to the Company (hereinafter referred to as “Excise Duty”); and

(f) the payment of any other Taxes now or hereafter levied or imposed by any Government Authority on the Service Provider or its subcontractors as a result of the performance of this Agreement.

9.3 Withholding taxes and Withholding certificates

9.3.1 The Company shall, at the time of its payments due to the Service Provider, withhold the necessary taxes at such rate as is required by any Government Authority, unless and to the extent that the Service Provider shall produce to the Company any certificate issued by a Government Authority (having authority to issue such certificate) entitling the Service Provider to receive the payments under the Agreement for a prescribed period without deduction of any tax or deduction at a lower rate.

9.3.2 The Company shall provide the necessary

withholding tax certificates to the Service Provider within the time stipulated by the relevant law to enable the Service Provider to file the same with the Government Authority as a proof of payment of such taxes.

9.4 Person Responsible for filing of returns / information to Government Authorities

9.4.1 The Service Provider shall be responsible for filing all necessary Tax returns (including, without limitation, returns for

Corporate Income tax, Personal Income tax, Service tax, Sales tax and Excise Duty) with the relevant Government Authorities in accordance with all applicable statutory requirements and shall be responsible for providing all information requested by such Government Authorities.

9.4.2 The Service Provider shall also ensure that

its sub-Contractors file such returns as stipulated by the relevant Government Authorities and furnish such information as requested for by the relevant Government Authorities.

9.4.3 The Company, with respect to the tax

withheld from the Service Provider in accordance with Clause 9.3 (Withholding Tax and Withholding Tax Certificates), shall be responsible for filing the withholding tax returns with the relevant Government Authorities in accordance with applicable statutory requirements.

9.5 Company’s rights, if treated as representative assessee by Government Authorities

In certain situations, a Government Authority may treat the Company as the representative assessee of the Service Provider and/or its subContractors and recover the Taxes due to the Government Authority by the Service Provider or its sub-contractors from the Company. In such situations, the Company shall have the following rights:

(a) The Company shall be entitled to

recover from the Service Provider, the Taxes paid on behalf of the Service Provider or its sub-contractors (together with any costs and expenses incurred by the Company in connection therewith) or to retain the same out of any amounts to be paid to the Service Provider or its sub-contractors that may be in its possession (whether due under this Agreement or otherwise) and shall pay only the balance, if any, to the Service Provider; and

(b) If the Company is required to furnish any details or documents in such capacity, the Company shall request the details or documents to be

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furnished to it by the Service Provider and the Service Provider shall immediately furnish the same to the Company. If the Service Provider fails to comply with the foregoing, any penalty/interest levied on the Company for non-filing or late filing of details or documents in this regard shall be recoverable from the Service Provider.

9.6 Indemnity

The Service Provider shall defend, indemnify and hold the Company harmless from and against any and all claims, liabilities, costs, damages and expenses (including court costs and legal fees) in connection with any Taxes which may be levied or imposed on the Service Provider or its sub-contractors by any Government Authority arising out of or in connection with the performance of this Agreement.

9.7 Changes in Law

If, after the date of execution of this Agreement, there is any change in law which results in a change in the rate of any Tax included in the Service Provider’s prices or rates or the introduction of a new Tax and such change results in an increase or decrease in the cost to the Service Provider of performing this Agreement then the Parties shall agree to a revision in pricing to reflect such change provided that: (a) the Party requesting such revision

shall promptly (and in any case prior to submission of the Service Provider’s final invoice under this Agreement) notify the other Party that such change in law has arisen; and

(b) the Party requesting such revision shall provide the other Party with documentary proof of such change in cost to the reasonable satisfaction of the other Party; and

(c) the provisions of this Clause 9.7 shall not apply to changes in Personal Income tax or Corporate Income tax or to changes in non-Indian Taxes.

10. TERMINATION

10.1 Either Party may, at any time and without cause, terminate all or part of this Agreement by giving no less than [30] days’ prior written notice to the other party. Provided that, if any Purchase Order has already been initiated and the work is in progress, then the Company only shall have the right to cancel/ terminate any Work under the relevant Purchase Order as specified in such Purchase Order without cause and with immediate effect.

10.2 In addition, the Company may terminate

all or part of this Agreement with immediate effect by written notice to the Service Provider if one of the following circumstances occurs:

(a) if the Service Provider breaches

any provision of this Agreement, provided that where remediable, the Company has notified the Service Provider of such breach and the Service Provider has upon receipt of such notice, failed to immediately and thereafter continuously proceed to remedy such breach to the Company’s reasonable satisfaction; or

(b) if the Service Provider becomes

insolvent or bankrupt or makes a composition or arrangements with its creditors; or

(c) if the Service Provider is wound up

or a resolution for its winding up is made (other than for the purposes of an amalgamation or reconstruction whilst solvent); or

(d) if the Service Provider has a

liquidator, provisional liquidator, receiver, administrator or an administrative receiver or manager of its business or undertaking appointed; or

(e) if the force majeure under Clause

14 continues for more than thirty (30) days.

10.3 In the event of cancelation/ termination

of all or part of this Agreement for any reason, the Company’s sole liability to the Service Provider in respect of such

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cancelation/ termination shall be to make payment of the Fees properly due under this Agreement up to the date of termination.

10.4 The expiry or termination of this

Agreement shall be without prejudice to the rights and obligations of the Parties up to and including the date of expiry or termination and shall not affect or prejudice any term of this Agreement that is expressly or by implication provided to come into effect on, or continue in force after, such expiry or termination.

11. CONFIDENTIALITY 11.1 The Company and the Service Provider

shall keep any information which either Party learns about or receives from the other pursuant to this Agreement in strict confidence and will not disclose the same to any third party without the prior written consent of the other Party. The foregoing restriction shall not apply in respect of information which the Company requires to disclose for the purpose of performing Services or which was in the possession of the disclosing party prior to this Agreement or which is required to be disclosed by any law, rule or regulation of any governmental agency or court order. The provisions of this Clause shall survive the expiry of termination of the Agreement for a period of 3 years.

11.2 The Service Provider shall not disclose

such Information(s) to any potential Subcontractors until such time and in manner agreed by Company in writing. The decision of the Company will be final and binding on the Service Provider in this regard.

11.3 The Service Provider shall use best

endeavours to prevent the authorised disclosure of the all information hereunder. Where any information is required to be disclosed under Clause 11.1, the Service Provider shall give prompt notice to the Company and shall use its best commercial endeavours to limit the extent of any such disclosure.

12. NOTICES

12.1 Any notice or other communication required or given under this Agreement shall be delivered in writing either by hand or by courier, registered mail with acknowledgment due, or fax to the address of the relevant Party set out in the Agreement (or such other address as may be notified by the relevant Party from time to time).

12.2 If a notice is delivered by hand or courier during normal business hours of the intended recipient it shall be deemed to have been received at the time of delivery otherwise on the next business day of the recipient. A notice sent by facsimile shall be deemed to have been received at the time when the sender’s facsimile machine acknowledges transmission provided however that if the time of acknowledgement of transmission is after 5.00pm on a business day of the recipient it shall be deemed to have been received on the next business day of the recipient.

12.3 All notices or other communications between the Parties shall be in the English language.

13. GENERAL LEGAL PROVISIONS 13.1 The Company shall be entitled to assign

this Agreement to an affiliate/subsidiary or on giving written notice to the Service Provider. Save as aforesaid, the Service Provider shall not be entitled to assign this Agreement or any part or any benefit or interest in or under it without the prior written approval of the Company which the Company may at its sole discretion accept or refuse.

13.2 This Agreement shall not be amended or

modified except by mutual agreement in writing between the Parties.

13.3 This Agreement and the all Schedules and

Attachments annexed hereto contains the whole agreement between the Parties relating to the subject matter of this Agreement, and supersedes any previous understandings, commitments, agreements or representations in respect of the subject matter.

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13.4 No delay or failure on the part of either Party to enforce from time to time all or any part of the terms and conditions of this Agreement shall be interpreted as a waiver of such terms and conditions.

13.5 Nothing in this Agreement shall, or shall

be deemed to, create an agency, a partnership or a relationship of employer and employee between the Parties. For the avoidance of doubt, nothing in this Agreement shall prevent or restrict the Company from entering into parallel Agreements with other parties for services similar or related to the Services.

13.6 Unless otherwise specifically stated, both

the Company and the Service Provider shall retain all rights and remedies, both under the Agreement and at law, which either may have against the other.

13.7 Each Party represents and warrants to the

other that (i) it has been duly registered and organised and is a validly existing legal entity under the laws of the jurisdiction of its incorporation and that it has full power, authority and capacity to enter into and to carry out its obligations under the Agreement and (ii) by performing the Services it will not be in breach of any other Agreement, agreement, license or permit or in violation of any law and (iii) it shall at all times act in accordance with applicable laws and regulations.

13.8 The Service Provider shall comply with all

safety instructions of the Company consistent with the provisions of the Agreement including, without limitation, the safety instructions of any of the Company's other Service Providers. Such instructions shall, if the Service Provider so requires, be confirmed in writing by the Company's Representative, so far as practicable.

13.9 The Service Provider shall not be entitled,

without the written consent of Company, to make any news release or public announcement concerning the subject matter of the Agreement or to refer to the Company, use its name or logo, in print or electronic forms for marketing or reference purposes.

13.10 If any provision of this Agreement is prohibited, invalid or unenforceable in any jurisdiction, that provision will, as to that jurisdiction, be ineffective to the extent of the prohibition, invalidity or unenforceability without invalidating the remaining provisions of this Agreement or affecting the validity or enforceability of that provision in any other jurisdiction, unless it materially alters the nature or material terms of this Agreement.

13.11 The provisions of this Agreement are solely for the benefit of the Parties. No other person are intended to have, nor will have, any rights whatsoever, under this Agreement, whether for injury, loss or damage to person(s) or property or for economic loss.

13.12 This Agreement may be executed in one or more counterparts, each of which will be deemed to be an original copy of this Agreement and all of which, when taken together, will constitute one and the same instrument.

14. FORCE MAJEURE

14.1 Neither the Company nor the Service

Provider shall be responsible for any failure to fulfil any term or condition of the Agreement if and to the extent that fulfilment has been delayed or temporarily prevented by a force majeure occurrence such as any (a) Act of God, (b) fire, flood, earthquake, (c) war, riot, insurrection and civil commotion, mobilization or military, call up of a comparable scope, which has been notified in accordance with this Clause 14 and which is beyond the reasonable commercial control and without the fault or negligence of the party affected and which, by the exercise of reasonable diligence, the said party is unable to provide against.

14.2 In the event of a force majeure

occurrence, the party that is or may be delayed in performing the Agreement shall notify the other party without delay giving the full particulars thereof and shall use reasonable endeavours to remedy the situation without delay.

14.3 Save as otherwise expressly provided in

the Agreement, no payments of whatever

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nature shall be made in respect of a force majeure occurrence.

14.4 Following notification of a force majeure

occurrence in accordance with Clause 14.2, the Parties shall meet without delay with a view to agreeing a mutually acceptable course of action to minimise any effects of such occurrence.

15. BUSINESS ETHICS 15.1 The Service Provider shall declare any

conflicts of interest with the Company including relationship or financial interest of any nature whatsoever with employees, managers, other suppliers, vendors or stakeholders of the Company.

15.2 The Service Provider shall not use the

services of any of the employees of the Company, directly or indirectly or enter into any sort of monetary transaction with the employees of the Company. The Service Provider undertakes that he has not given, offered or promised to give directly or indirectly any bribes, commission, gift, consideration, reward, or inducement to any of the employees of the Company or their agent or relatives for showing or agreeing to show favor or disfavor to any person in relation to this Agreement or forbearing to do or for having done or forborne to do any act in relation to the obtaining or execution of the aforesaid undertaking, by the Service Provider, or his partners, agent or servant or any one authorized by him or acting on his behalf. The Service Provider undertakes that in the event of use of any corrupt practices by the Service Provider, the Company shall be entitled to terminate the Agreement forthwith and recover from the Service Provider, the amount of any loss arising from such termination. A decision of the Company or his nominee to this effect that a breach of the undertaking had been committed shall be final and binding on the Service Provider.

15.3 If at any time during execution or

performance of this Agreement the Service Provider if faced with any undue demand, request for gratification or favor from any employee of the Company or a person connection with such employee,

the Service Provider must report the same immediately at [email protected].

15.4 The Service Provider agrees to comply

with the provisions of the Company’s Supplier Code of Conduct and the Company’s Human Rights Policy including the Modern Slavery Act and in case of breach thereof, the same shall be treated as a breach of this Agreement.

15.4.1 The Service Provider shall maintain records

and provide to the Company upon request such records and evidences, as the Company may reasonably require, confirming the Service Provider’s compliance with the obligations under Clause 15.4.

15.5 The Service Provider shall comply with

the Anti-Bribery and Corruption (AB&C) requirements as applicable to them.

15.6 The Company shall have a right to initiate

"audit proceedings" against the Service Provider to verify compliance with AB&C requirements. Such audit may be carried out by Company or by a reputed agency to be appointed by Company at the sole discretion of Company. The Service Provider shall extend full cooperation for smooth completion of the audit mentioned herein.

15.7 Notwithstanding anything in this

agreement, Company shall have right to terminate the Agreement forthwith in case, it is found that the Service Provider has failed to comply with AB&C requirements.

15.8 The Service Provider may submit/report

'Complaints' pertaining to any violation to the Company's ethical business practices as specified in the Company's Code of Conduct Policy.

External stakeholders such as vendors,

customers, business partners etc. have the opportunity to submit 'Complaints'; however, the Company is not obligated to keep 'Complaints' from non-employees confidential or to maintain the anonymity of non-employees. We encourage individuals sending 'Complaints'/raising of

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any matter to identify themselves s instead of sending anonymous 'Complaints' as it will assist in the effective complaint review process.

Post review, if the complaint is found to

be have been made with malafide intention, stringent action will be taken against the complainant. We encourage reporting genuine 'Complaints' and those submitted in true faith.

All the ‘Complaints’ under this policy

should be reported to the Group Head-Management Assurance at the following address:

Group Head – Management Assurance, Vedanta, 75 Nehru Road Vile Parle (E), Mumbai 400 099 ‘Complaints’ can also be sent to the

designated e-mail id: [email protected]

16. GOVERNING LAW AND DISPUTE

RESOLUTION

16.1 This Agreement shall be governed by, construed and enforced in accordance with the laws of Punjab, India.

16.2 Any dispute or difference whatsoever arising between the parties out of or relating to the interpretation, meaning, scope, operation or effect of this Agreement or the existence, validity, breach or anticipated breach thereof or

determination and enforcement of respective rights, obligations and liabilities of the parties thereto shall be amicably settled by way of mediation. If the dispute is not conclusively settled within a period of twenty-one (21) days from the date of commencement of mediation or such further period as the parties shall agree in writing, the dispute shall be referred to and finally resolved by arbitration under the Arbitration and Conciliation Act, 1996 (as amended from time to time), which are deemed to be incorporated by reference into this clause. The arbitration shall be conducted as follows:

(i) A sole arbitrator shall be appointed in case the value of claim under dispute is less than ₹ 50,00,000 (Rupees Five Million Only) and in any other event by a forum of three arbitrators with one arbitrator nominated by each Party and the presiding arbitrator selected by the nominated arbitrators.

(ii) The language of the mediation and arbitration proceedings shall be English. The seat of arbitration shall be Bathinda, Punjab.

(iii) The award made in pursuance thereof shall be final and binding on the parties. The right to arbitrate Disputes under this Agreement shall survive the expiry or termination of the Agreement.

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ATTACHMENT 1 to SCHEDULE I

SCOPE OF WORK

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ATTACHMENT 2 to SCHEDULE I COMPENSATION SCHEDULE 1. COMPLETENESS OF PRICING

All rates, sums, charges and prices referred to in this Schedule: (a) are stated in currency as mentioned in the service list. (b) are considered complete and fully inclusive in respect of the services being provided and

no additional rates, sums, charges or prices shall be paid, except as expressly stated in the Agreement;

(c) shall remain fixed and firm and shall not be subject to amendment for any cause, except as expressly stated in the Agreement.

The cost of any item where the price is left blank shall be deemed included elsewhere.

2. Taxes The prices and rates set out in this Schedule II (Compensation Schedule) are:

(a) inclusive of all Indian direct taxes (including without limitation personnel taxes, withholding taxes and corporate taxes) now or hereafter levied or imposed on the Service Provider; and

(b) inclusive of all non-Indian taxes (whether direct or indirect) now or hereafter levied or imposed on the Service Provider; and

(c) Inclusive of all taxes/levies/duties as applicable except for Service Tax which shall be paid

over and above the below mentioned charges as per applicable rates, current rate is [ as mentioned in service line items ]%.

3.Withholding Tax

TDS shall be deducted as per the applicable rates under Income Tax Act and same shall be in Service Provider’s account only. 4. Mobilization period,Validity & Payment Terms for the contract 5. Other terms & conditions:- A. SAFETY: 1. The Contractor shall take all safety precautions and provide adequate supervision by competent persons in order to do the job safely and without damage to plant, personnel, and the environment. The detail safety instructions and guidelines can be collected from the Engineer/Manager in charge and the Safety Heads of respective area.

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2. Compliance to Safety Rules & Regulations: Contractor shall be responsible for and shall follow safety Act & rules under the provision of factory Act 1948, PFR 1952, Indian Electricity rules 1956, Gas cylinder Rules 2004, Petroleum Act 1934 , BOCW and other applicable acts & rules as amended up to date and other statutory safety rules & regulations in force during continuation of the contract. 3. Safety Training: All contractor employees should undergo Safety Induction training before putting them on the job at our Site. No worker/Employee should be allowed inside the plant without gate pass .Gate pass will be issued only after undergoing the safety induction training .Employees should report in safety training with temporary gate pass( only for training ) ,safety shoe ,helmet and goggles .The contractor will ensure that Job specific Safety training is provided to their employees from time to time by providing them the knowledge about the Occupational Hazards and their countermeasures. 4. PPEs: Contractor shall provide all necessary safety gadgets as applicable for the work area, like safety shoes, safety helmets, goggles, suitable respirators, dust masks, ear plugs, hand gloves etc. etc. to all his employees . All personal protective equipment (PPEs) should be of ISI grade confirming to recognized bodies (certified by EN/CE/NIOS/CLI) standards. The mandatory PPEs are Helmet, Safety Shoes, Goggles, Hand Gloves and Reflective Jacket. Based on the requirement in particular area/job specific PPE like Ear plug/muff dust respirator, mask, safety belt , specific gloves, suits, gumboot etc. Approval of Quality of PPE shall be approved by TSPL HSE Department a) Safety Helmets as per IS 2925. b) Good quality leather safety shoes as per IS 10348; 1982 / IS 5882. c) Good quality leather safety shoes as per IS 11225; 1985 for women workers. d) Double Lanyard Full body Safety harness as per IS 3521, with SH 40 hook for workers working at Height more than 1.8 M. e) For welding PPEs such as Apron (as per IS 6153), Welding Google's (as per IS 1179), Face shield, Leather Gloves & elbow guards should be used. f) Jean Jacket, Cotton Pant, Cotton Shirt & Cotton apron in hot zone area to be used. No entry with synthetic cloths will be permitted. g) Chemical resistant apron as per IS 4501. h) Good quality ear plugs and / or ear muffs as per IS9167. i) Good quality Safety Goggles, Dust mask & area specific applicable respirators as per IS 8522, (HF respirators for Pot Room, HCL respirator of HCL Acid handling, Ammonia Respirator

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for Ammonia Handling) to be used .These respirators should be Checked and approved by our Safety Department. j) Gumboots as per IS 5557, for the activities involving water logged areas. The contractor should provide quantity of PPEs proportionate to the no of manpower deployed & the Nature of the job at the site .In case of ambiguity our Safety Department Guideline on brand and Quality of PPEs will be final. 5. At any point of operation of contract the contractor shall remain liable to report to the safety department with respect to ensuring Safety at the site. 6. Road Safety norms: All Employees of contractor including the vehicles used by them should strictly follow Road Safety Policy for our TSPL site while working inside the plant premises. Contractor shall ensure reflective sticker on Helmet and bicycle. 7. Work Permit :Necessary work permits ( Working at Height, Hot work permit, Working in confined Space, Excavation, Electrical work ,Working on critical equipment cranes, lifts , Working on dangerous lines etc )should be taken from relevant authority before starting such jobs. All safety guidelines mentioned in these work permits should be strictly adhered to. 8. Height Works: Supervisor must be present at site during height jobs or other risky jobs & take Necessary work permits. Suitable scaffolding should be provided for workmen for all works that cannot safely be done from the Ground or from solid construction except such short period work as can be done safely from ladders. When a ladder is used an extra Worker shall be engaged for holding the Ladder and if the ladder is used for carrying material as well, suitable footholds and handholds shall be Provided on the ladder and the ladder shall be given an inclination not steeper than 1 in 4 (1 horizontal and 4 vertical). Safety nets conforming to IS 5175 should be provided, if required. Scaffolding must be tested by trained scaffold working at height and properly tagged "Safe to Use" date of inspection and signature. Person working at height must have height pass issued by TSPL HSE Department 9. Electrical Works: Strict enforcement of Lockout & Tag out system to be ensured & necessary work permits to be taken before starting of the Job. Mandatory use of Arc Protection Suit for work on electrical systems. Suitable Arc flash suit as per voltage shall be used by the Contractor. During maintenance contractor shall procure LOTO Equipment as per

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Vedanta Safety Standards. This is applicable for maintenance contractors. 10. Excavation, trenching & Demolition: Necessary work permits to be taken before any Excavation & Demolition work. All trenches 1.2 meters or more in depth shall at all times be supplied with at least one ladder for each 50 meters length or fraction thereof. Ladder shall be extended from bottom of the trenches to at least 1 meter above the surface of the ground. The sides of the trenches which are 1.5M in depth shall be stepped back to give suitable slope or securely held by timber bracing, so as to avoid the danger of sides to collapse. The excavated materials shall not be placed within 1.5 meters of the edge of the trench or half of the trench width whichever is more. Cutting shall be done from top to bottom. Under no circumstances undermining or under-cutting shall be done. Before any demolition work is commenced and also during the progress of the demolition work- a) All roads and open areas adjacent to the work site shall either be closed or suitably protected b) No electric cable or apparatus which is liable to be a source of danger shall remain electrically charged. c) All practical steps shall be taken to prevent danger to persons employed from risk of fire or explosion or flooding. No floor, roof or other part of the building shall be so overloaded with debris or materials as to render it unsafe. All necessary personal safety equipment as considered adequate by the Engineer -In-Charge should be kept available for the use of the persons employed on the Site and maintained in condition suitable for immediate use, and the contractor shall take adequate steps to ensure proper use of equipment by those concerned. 11. Pressure vessels ,Lifting Tools,& Lifting machines : All Pressure vessels ,Lifting tools ,tackles, machines & mobile equipment like cranes, hydra, forklifts, etc. should comply to Safety Standard & should have valid test certificate as per PFR and maintained as per the prescribed guidelines . A list of all such Pressure vessels, lifting machines, tools and tackles along with copy of test certificates must be submitted to concern Safety Head before taking into use. All Pressure vessels to have a clear marking of Safe Operating Pressure & to be operated below the Safe Operating pressure at all-time complying to the Guidelines.

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Every crane driver or hoisting appliance operator shall be properly qualified and no person under the age of 21 years should be in charge of any hoisting machine including any scaffolding, winch or give signals to the operator. Contractor to ensure Colour code for tested equipments. The guidance shall be issued by TSPL HSE Department on quarterly basis. The below mentioned things to be ensured. " Record of all lifting tools, tackles, lifting machines, hoists & lifts to be maintained in a Register as per Factory Act 1948 (Section 28,29). " All Lifting gears to be marked with Identification No, SWL, Testing date, Due Date of Testing. " Annual & half yearly inspection as applicable to be carried out for all lifting machines, chains, ropes, & lifting tackles by competent person as per PFR rule & Record to be maintained as per PFR. " Half yearly inspection to be carried out for all hoists & lifts by competent Agency. Record of the same to be maintained as per Form 7A of Orissa Factories Rule. " Quarterly inspection color coding to be carried out by respective Agency /Department. (Q1-Green;Q2-Blue;Q3-Yellow;Q4;Orange, Rejected; Red). " Physical verification to be done at site for all lifting tools, tackles, Slings & ropes by respective agency as per checklist. " Periodic maintenance of All Lifting tools & tackles to be covered under Preventive Maintenance schedule of the plant. " Forklifts /pallet trucks to be tested annually and record to be maintained. " All Lifting machines to be painted, fitted with fluorescent stickers (both front & back) & maintained in good condition with daily checking register by the drivers. " EOT cranes should have at least one independent escape route and shall be provided with Warning/alarm devices while in operation. Standard hand signals to be displayed and training to be provided to the operators, riggers & signalers. " All hooks shall be provided with spring retainers/latch. " Hydra is strictly prohibited for shifting the materials .It can only be used for lifting the loads. Hydra crane shall comply with run over protection as per standard attached. Also all hydras to have clear marking of SWL in bold letter on different height of Boom, a display of load chart, copy of test certificate & board mentioning the details of Equipment no, SWL, Testing Date, Due Date of testing " All lifting tools and tackles shall comply to BIS and applicable reference standard number to be quoted for each equipment.

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" Any incident of failure/breakdown to be properly investigated and recorded. " Pre-employment & periodic medical examination including Audiometry & Color blindness test to be carried out for all EOT crane operators & drivers of lifting machines(Hydra, Forklift etc.). & record to be maintained. 12. Competency: All contractors engaging 100 or more workers will have to keep full time qualified & experienced (minimum 5 years) Safety Officers with qualifications. Their Competency shall be verify by Head-HSE. Factory Rule, 1952. Other contractors should appoint a safety supervisor/co-coordinator for coordinating safety activities with company safety office. Competency certificates (Experience and/ or statutory qualification) for welders, Riggers, electricians, Heavy earthmoving machine operators/drivers and other such specialist workers, shall be submitted by each contractor to the respective department HODs. 14. Health Check Up : Contractor shall furnish Health Record as per Punjab Factory Rules and Vedanta Sustainability Guidelines. Specific medical examination such as Spirometry, Eye test, Audiometry is also required. Vertigo and other required test for working at Height Confined space entry shall be carried out. Based on the Medical Report Certifying surgeon shall issue the fitness certificate. TSPL Medical Officer Reserve the right to disqualify the fitness anytime is found unsatisfactory. Contractor shall disclose & furnish the past medical History of worker suffering from communicable disease or disease like epilepsy, vertigo and Heart Disease. 15. Vedanta Sustainability Frame Work and Life Saving Rules Compliance: Contractor shall ensure compliance Vedanta Sustainability Frame Work and new safety Standards. Life Saving Rules is an integral part of HSE Management which is considered as ZERO TOLERANCE POLICY. Hence in no case contractor should violate the same. 16. Environmental Aspect: All precautionary measures to be adopted at workplace to prevent Environmental Damage. 17. Maintenance of Safety Records & Reporting: The Contractor should maintain applicable legal registers. Apart from the same they should maintain register of PPEs Issue, Training of employees, Accident/Injury register, & Health checkup, Equipment details, Operator Authorization details etc. Following information to be submitted at the end of the every month (before 3rd of next month) to the respective Safety HODs directly with copy to site in charge. A. - Total nos. of employees = - Working hrs / days =

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-Duration of contract (in days) = B. STATUS OF SAFETY - GADGETS - Nos. of helmets = - Nos. of safety belt = - Nos. of goggles = Welding Goggles = Grinding Goggles = General Goggles = - Nos. of hand gloves = - No. of safety shoe / gum boot = - Length of barricading tapes = - Status of warning tags (like =radiography, road blocking, no entry etc. use) C. INCIDENT STATUS Name of safety representative = - Nos. of minor injuries = - Nos. of three days injuries = - Nos. of major injuries = - Nos. of fatalities (if any) = D. INSPECTION RECORD - Gas cutting set & welding =machine inspected on & by - List of hand tools updated on = - Hand tools inspected on & by = - Ladders & lifting tools inspected =on & by E.TRAINING RECORD: No of Training Conducted & Topics Covered- No of People Trained with Details of Trainer- Signature of Site In charge Name of the Contractor: #######. Any additional report to be submitted will be decided by our Safety HOD's at the site. 18. Responsibility: Ensuring Safety and prevention of any accident /incident of the employees of the contractor will be the sole responsibility of the contractor. 19. Violation & Penalties: In case of any violation of safety measures by the contractor or his employees will be taken seriously and in such situation our plant reserves it's right to cancel this contract and /or suitably penalize the contractor as under

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Sl No Description of Unsafe Act/ Conditions Penalty rate / Violation ( Rs ) 1 Nonuse of basic PPEs like (Safety helmet, Safety shoes 200/- 2 Using welding machine without proper plug pin, ear thing & ELCB 500/- 3 Taking power by inserting naked wires instead of appropriate plug. 200/- 4 Taking electrical supply from DB without ELCB/RCCB 500/- 5 Not using earth connection for electrical gadgets like grinder, drilling machines, pump motors, blowers etc 500/- 6 Nonuse of welding shield during Welding & nonuse of Safety goggles during cutting/girding/drilling 200/- 7 Not following Safety Work Permit System 500/- 8 Not following the safety advice/instruction of our safety official.- 5000/- 9 Bypassing safety interlocks or removal of safety guards 500/- 10 Operating Hydra without SSL Safety Guideline 1000/- Using chain blocks or lifting tackles which are not tested or not meeting safety standards 1000/- 11 Rolling of gas cylinders on the ground during transportation from one place to another place 200/- 12 Using gas cutters without flash back arrestors, damaged hose, and leaky cylinders 200/- 13 Adopting short cut methods (Any Un-safe Act) 200/- 14 Violation of Road Safety norms (As per policy 1st time - 2nd time onwards 200/- 15 Violation of Road Safety norms (As per policy 2nd time onwards 500/- 16 Violation More than twice - Ban of Vehicle and removal of person from site. 17 Non availability of Gate pass at 50/- person 18 For any accident due to the negligence of the contractor/ contractor's deployed agencies/ workers or sub-contractors following penalties shall be levied as mentioned below 18a Fatal Accident 10Lac/- or 50% of Contract value (which one will be Lower ) 18b a. For Major/reportable accident (Permanent Disability) 5.0 Lacs 18c b. for reportable accident (Non-Permanent Disability) Rs 50000/-

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20) Damages: Charges towards any damage of equipment/material at our site caused due to miss handling by contractors workers/vehicle shall be deducted from contractor's bill after assessment by our Engineer in charge .The assessment of our Engineer In charge shall be final and binding on the contractor. All of the contractor's vehicle entering into factory premises must be comprehensively insured. 21. No worker of contractor/contracting farm and the contractor himself shall be allowed to consume alcoholic drinks or any narcotics within the plant premises. If found under the influence of the above, the contractor /contracting firm shall have to change /replace him, failing which we may terminate the contract. 22. Smoking within the battery area, tank farm, flammable material storage area & other such high risk areas is strictly prohibited. Violators of the no smoking rules shall be discharged immediately. Handling of flammable materials inside plant premises should be dealt with adequate protection so as to avoid fire & Explosion .Instruction from respective Department and Safety Department should be followed strictly for compliance of the same. 23. The contractor /contracting firm shall not deploy any person suffering from any contagious, loathsome or infectious disease. The contractor should ensure high standard of Hygiene in his workplace to prevent out break /spreading of contagious disease. 24) Reporting of Accidents & Dangerous Occurrences :The contractor shall immediately upon knowing of any accident ,damage or losses in which he is involved on the site should inform the area in charge .The contractor shall not negotiate ,pay settle, admit or repudiate any claim without the consent of our company management. 25) Violation of life saving rules shall be taken seriously and in case of violation of any rules penalty of Rs. 500/- shall be imposed. In case of second violation Rs. 2000/- shall be levied and on third time person shall be agreed to leave the workplace and suitable penalty action shall be taken against the contractor as per management decision. 26) Consuming Alcohol or drugs in strictly prohibited and in case violation person shall be removed immediately. 27) Score card system shall be followed and Separate guidelines for same shall be issued by HSE Dept. Time to time and accordingly appreciation and Penalty shall be imposed. A sample copy is attached as reference. Point # 14shall vary as

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per nature of Job. Safety Score card may change time to time based on company policy. Monthly HSE Score Card Name of Contractor- A Service provider in Turbine area Month- Sr. No. Parameter Max Marks Marks Obtained Remark Scoring Criteria 1 First aid cases 10 For each First Aid case five marks shall be deducted 2 Incident cases/Property Damage/Fire incident/ Environmental Incident 4 For each incident case four marks shall be deducted 3 Compliance of Vedanta Sustainability Frame work 8 For each violation of Vedanta Sustainability framework 1(One) marks shall be deducted. It Includes: a. Fleet Management b. Machine Guarding up keepment and fixation c. Waste management at workplace d. Health checkup of employees 4a Reporting of Near miss, Unsafe Acts and conditions 8 Reporting of Near miss -10 (Full marks - 5), Unsafe conditions -30 (Full marks - 3) Unsafe Acts -20 (Full marks - 2) 4b Percentage compliance of NCR raised in Portal or Various Audits 4 For each non compliances one mark shall be deducted 5 No. severe safety Violation 5 5 marks shall be deducted for severe safety violation (for 10 nos of 4s - 5 marks and for 5 nos 5S , 5 marks will be deducted) 6 a. Number of Tool Box / HSE Talks - 5 marks b. Contractor Weekly HSE meeting - 5 marks 10 a. Prorata basis (No. of Safety talk / month divided by average man power) b. Prorata basis 7 HSE training, 5 8% coverage of total manpower per month 8 Legal compliance status (Testing of Lifting Tools & Tackles, Safety Belts (full body harnesses, Fall arresters) 4 1 mark will be deducted for each non compliances observed on site. 9 PTW Compliance 8 For deviation in each PTW case two marks shall be deducted 10 a. Condition of Hand Tools/Equipment/ Vehicle of the contractor b. Condition and compliance for movable equipment 4 a. 1(One) mark will be deducted for every non compliances observed on site.

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b. 1(One) mark will be deducted for every non compliances observed on site. 11 Housekeeping (including waste removal from workplace after completion of work) 5 1(One) mark will be deducted for each non compliances observed on site. 12 Quality of PPEs and scaffolding compliance 5 1(One) mark will be deducted for every 1 non compliances observed on site. 13 Safety motivational programme and other initiatives 5 Compliance of safety motivational programme and submission of relevant documents 14 job specific compliance a Are Water spillage are being cleaned daily 2 Marks will be Zero If found any non-conformity b Fire protection system readiness 1 Marks will be Zero If found any non-conformity c Insulation & Cladding completeness 1 Marks will be Zero If found any non-conformity d Identification & mitigation of any gas leak 2 Marks will be Zero If found any non-conformity e Are update list of vehicle driver/WAH are available 3 Marks will be Zero If found any non-conformity f Is 5S initiative followed 3 Scoring shall be done by TSPL BE Dept. based on 5S Compliance. Marks will be Zero If found poor Housekeeping g Are all signage are available 1 Marks will be Zero If found any non-conformity h Behavior of workers 2 Marks will be Zero If found any non-conformity TOTAL SCORE 100 Signature of Contractor In charge Signature of TSPL Safety Officer B.RISK PURCHASE In the event of any failure on contractor part to execute the Order as per the terms mentioned therein, owner shall be at liberty to either: a) Continue with the contractor with due liquidated damages; or b) Engage any other agency, parallel to the Contractor, to complete part of the balance work at the risk and cost of the Contractor; or c) Cancel the Service Order and get the balance work done from any other agency at the risk and cost of the contractor. C. INSURANCE:-

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A) # Without limiting the obligations and responsibilities under this contract, service provider shall procure and maintain an "All Risks" Insurance, Workmen's Compensation Insurance Group Personnel Accident Policy, Fire and Theft Insurance and such other policies for his own Materials/ Plant/ Machinery/ Equipment/Workers and the Civil Structures. All policies shall be with an endorsement of "PRINCIPALS INTEREST PROTECTED" clause. Besides, the service provider shall also take Third Party Liability Policy for both, Personnel and Property damages. # Service provider shall keep the TSPL indemnified from any liabilities on account of injury /loss/damage to any labour/ personnel/ property/ Plant / Machinery / Civil Structure. Copy of such insurance policies shall be submitted to our Engineer in-charge before start of the work. # TSPL shall be the principal beneficiary of the policies along with service provider and shall reserve the exclusive right to assign the policy. TSPL also reserves the right to approve/disapprove the Insurance Company selected by the service provider and/or issue the aforesaid policies on service provider's behalf. # This insurance coverage shall continue during the entire period of Contract. At the request of TSPL, the Service provider shall furnish to TSPL the relevant policy and premium receipt in respect of the said insurance. The risk, cost and consequence of the Service provider's failure to arrange for insurance coverage as specified above shall to be solely to Service provider's cost and account and TSPL shall have no liability whatsoever thereof. # In the event of loss or damage, service provider shall be solely responsible to lodge the claims and settle the same. Service provider shall proceed with repair or replacement of any works thereof without waiting for settlement of the claim. It is further clarified that neither extension of Completion Schedule nor any extra claim or addition to contract Price shall be admissible on account of insurance # The service provider shall arrange for 3rd party insurance so has to cover all accidents that are caused on TSPL's site by the service providers equipment &/ or service providers employees # The benefits and obligations of this agreement shall not be directly or indirectly assigned or dealt with by the service provider. TSPL shall not be liable for any third party liabilities / claims etc.

15

B) Safety and Security: Service provider shall be responsible for the safety and security of all his men and material. Service provider shall provide all safety equipment to all his team members.Service provider shall provide adequate coverage against any accident met by his team during period of contract. Service provider shall indemnify the owner(TSPL) against any claim arising in this regard.

3x660 MW Thermal Power Plant Talwandi Sabo Power Limited, Mansa, Punjab

Owner:

Talwandi Sabo Power Limited, Mansa, Punjab

Consultant:

L&T – SARGENT & LUNDY LIMITED

L&T – S&L Job No.: HD18117000

Title:

CONSTRUCTION OF DIVIDE BUND FOR ASH POND FACILITY

Doc/Drg No.: HD18117000-VB00-00-UEV-170001 Rev No.: 00 Total No. of Pages : ___

Revision Status:

Rev No.

Prepared Reviewed Approved

Name Date Name

Date Name Date Mech. Elec. Civil C&I SES

00 AKS 11DEC2017 JCS 11DEC2017 SSG 11DEC2017

Section xx

TALWANDI SABO POWER LIMITED

L&T-S&L LIMITED Construction Divide bund for Ash Pond Facility

EPC TENDER PACKAGE TECHNICAL SPECIFICATION FOR

GENERAL CIVIL WORKS Rev.: 00 (Draft)

Date: 12.DEC.2017

L&T-S&L Job No.: HD18117000 Document No.: HD18117000-VB00-00-ZEN-170001 Page:

Revision Summary Sheet Rev No.

Details / Description Date

00 PRELIMINARY 12DEC2017

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TABLE OF CONTENTS

1.0 INTENT OF SPECIFICATION .................................................................................................. 3

2.0 SCOPE OF WORK .................................................................................................................. 3

3.0 CODES AND STANDARDS .................................................................................................... 4

4.0 TECHNICAL SPECIFICATION ................................................................................................ 5

5.0 DRAWINGS ............................................................................................................................. 5

6.0 LAYOUT AND LEVELS ........................................................................................................... 5

7.0 SITE CONDITION AND INFORMATION ................................................................................. 5

8.0 EXECUTION METHOD & SCHEDULE.................................................................................... 6

9.0 TESTS FOR MATERIAL AND WORKMANSHIP .................................................................... 7

10.0 HAUL ROADS ......................................................................................................................... 7

11.0 BORROW PITS ........................................................................................................................ 7

12.0 PREVENTION OF POLLUTION .............................................................................................. 8

13.0 SAFETY MEASURES .............................................................................................................. 9

14.0 EQUIPMENTS AND MACHINERY .......................................................................................... 9

ANNEXURE – I: SCHEDULE OF ITEMS FOR ASH POND DIVIDE BUND ................................... 10

ANNEXURE – II: DETAILED TECHNICAL SPECIFICATIONS ..................................................... 13

ANNEXURE – III: BID DRAWING ................................................................................................... 14

ANNEXURE – IV: SCHEDULE OF PARTICULARS (BY BIDDER) ............................................... 17

SCHEDULE– 1: SCHEDULE OF GENERAL PARTICULARS OF THE BIDDER .......................... 18

SCHEDULE– 2: SCHEDULE OF EXPERIENCE LIST OF BIDDER .............................................. 19

SCHEDULE– 3: SCHEDULE OF DOCUMENTS TO BE SUBMITTED ALONG WITH BID .......... 20

SCHEDULE– 4: SCHEDULE OF DOCUMENTS TO BE SUBMITTED AFTER AWARD OF CONTRACT..................................................................................................................................... 21

ANNEXURE – V: SUB SOIL DATA ................................................................................................ 23

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1.0 INTENT OF SPECIFICATION 1.1 M/s. Talwandi Sabo Power Limited (TSPL or Client), Mansa, Punjab has intended to

construct divide bund in their already charged ash pond facility in order to facilitate the dyke raising in phased manner for 3x660 MW Thermal Power Plant at Talwandi Sabo, Mansa, Punjab. M/s. TSPL has employed L&T-Sargent & Lundy Limited (L&T-S&L or Consultant) for consultancy service of this divide bund design. Present document furnishes key information and design data required for the divide bund construction.

1.2 Project Information

For site information, refer bid drawings (Annexure III) which shows the overall layout of existing ash pond area. It is important to note that this ash pond is already in operation and filled with ash. At time of preparation of the present document, the status of the ash pond filling is shown in the given bid drawings and bidder shall visit the site prior to quoting for the assignment. It is possible that at time of actual construction, the situation of the ash pond filling may be different than it is shown in the furnished sketch (Annexure III) and bidder shall note this aspect while submitting the best offer.

2.0 SCOPE OF WORK

2.1 The broad scope of Work shall include all Civil and Structural of new divide bund

across the existing ash pond facility in accordance with specifications, approved drawings, schedule of items and direction of the Engineer but shall not be limited to the following: o Site development works consisting of site clearance and removal of debris.

o Preparation of subgrade for new earthen embankment.

o Providing and laying cut-off trench using compacted clay

o Embankment filling with available excavated earth or borrowed earth and fly ash

deposited in the ash pond as per the requirements specified in Annexure-II and III.

o Providing and laying HDPE liner (600 micron) as shown in the respective drawing.

o 150 thick bottom ash cushions below HDPE liner.

o Protective layer in form of fly ash brick pitching over HDPE liner.

o Providing subsurface drain arrangement in longitudinal and transverse directions on the top of divide bund to intercept and safely divert storm precipitation.

o Construction of rock toe as per the requirements specified in Annexure-III.

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o Construction of Blanket drain and chimney drain

o Constructing RCC ducts at outlet.

o Other related works like fly ash brick pitching, surface drains, trench excavations etc

whether specifically mentioned or not any work required to construct safe and serviceable divide bund shall be including in the contractor’s scope of work.

2.2 The work to be performed under the specification consists of providing all labour,

supervision, materials, scaffolding, power, fuel, water, construction equipment, testing equipment, tools and plants, supplies, transportation, all incidental items not shown or specified, but reasonably implied or necessary for successful completion of the work including Contractor’s, and where necessary manufacturer’s expert supervision in strict accordance with the drawings and specifications.

2.3 The unit rates quoted by the Contractor for all the items shall be deemed to be inclusive of all the operations specified in the above paragraphs and also of any other contingency whatsoever required for completion of the work. No extra shall be payable to the Contractor on these accounts for other protective enabling works.

2.4 The Engineer shall have the right to alter / modify the scope of work specified in above paragraphs to meet the site specific requirements. In case of any dispute, decision of the Engineer shall be final and binding to the Contractor. Work to be provided by the Contractor

The work to be provided by the Contractor, unless specified otherwise, shall include but not be limited to the following:

i) Furnish all labour, supervision, services, materials, equipment, tools and plant transportation etc. required for the work.

ii) Submit for approval detailed schemes of all planning/operations required for executing the work e.g. material handling, placement, services, approaches etc.

iii) Execution of work as per scope of work under skilled and competent supervision as per the execution methodology approved by the Engineer.

iv) To carry out quality checks/ tests and submit results of tests to the Engineer to assess the quality of work as per approved field quality assurance plan prepared by the Contractor.

v) Work method statement adhering to the respective safety standards

3.0 CODES AND STANDARDS

All standards and codes of practice referred to herein shall be the latest editions including all applicable revisions and amendments issued.

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All works shall be carried out as per the standard codes specified in relevant Clauses of Technical Specifications and as attached in Annexure-II of this specification. In case of conflict between the specification and the IS codes / other codes referred to herein, the former shall prevail.

4.0 TECHNICAL SPECIFICATION

The detailed technical specifications for works associated with Ash Pond Divide Bund are in Annexure-II of this document.

5.0 DRAWINGS

The work has to be executed as per the ‘APPROVED FOR CONSTRUCTION DRAWINGS’ with additions, alterations, and modifications made from time to time as required or approved by the Engineer and also according to any other drawings that would be supplied to the Contractor progressively during the execution of the Contract by the Engineer. Preliminary drawings as listed in Annexure-III are enclosed along with this document ‘FOR BID PURPOSE ONLY’ (LATER). In case contractor would like to propose any alternate arrangement or scheme for the details shown in the given drawings (Annexure III), he/she shall submit the detail scheme with the bid in order to understand the merit of the proposal.

6.0 LAYOUT AND LEVELS

The layout and levels of all components of existing ash pond shall be as per approved drawings. Contractor shall extend all services i.e. instruments, men and materials, to the Engineer for checking the detailed layout and levels, at his own cost. However the Contractor shall be solely responsible for correctness of the layout & levels. Permanent reference pillars with respect to established plant benchmarks shall be established by the Contractor on the top of existing ash dyke at his own cost and under no circumstances shall the Contractor remove or disturb any permanent benchmark without the approval of the Engineer. The Contractor shall carefully maintain and protect all benchmarks and reference forms and shall layout all his works by accurate reference thereto. Contractor shall submit the proposal/ scheme for establishing the permanent benchmarks troughout the construction phase and shall hand over it to the Owner at the end of construction.

7.0 SITE CONDITION AND INFORMATION

(a) The Contractor shall inspect and examine the site and its surrounding and shall satisfy himself before submitting his bid about the nature of the ground and subsoil, the form and nature of the site, the quantities and nature of work and sourcing and materials necessary for completion of the works and the means of access to site and shall himself obtain all necessary information as to risks, contingencies and other circumstances which may influence or affect his tender. An abstract of sub-soil data

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(bore log details pertaining to raw water reservoir) are furnished in Annexure – V (whish is of some other areas of plant). The soil data and properties of ash furnished in Annexure V for reference purpose is in good faith and only for guidance of the Bidder/ Tenderer. In case contractor would like to conduct the special geotechnical investigations for the divide bund construction, he/she may inform the Owner in advance. The Owner/Purchaser shall not entertain any claim on account of this at a later date, if the existing sub-soil data is at variance with the attached details.

(b) The Contractor shall take all necessary steps to satisfy HSE requirements, as per all

statutory requirements and norms. He shall also take all necessary precautions to protect his equipment, structures, facilities and buildings etc. from damage. In case, any damage occurs to the Owner/ Purchaser’s facilities/ existing structures, etc. due to the activities of the Contractor on account of negligence, ignorance, accidental or any other reason whatsoever, the damage shall be made good by the Contractor at his own cost to the satisfaction of the Purchaser. The Contractor shall also take all necessary safety measures, at his own cost, to avoid any harm/injury to his workers and staff during the execution of the work without any obligation to the purchaser.

(c) Many other agencies/Contractor will be working simultaneously at the project site.

The Contractor shall co-ordinate with other agencies during execution of the work. The Contractor shall maintain cordial relation with all such agencies working at site. Front shall be released to the Contractor progressively according to completion of work by other agencies.

8.0 EXECUTION METHOD & SCHEDULE

(a) The Bidder shall submit proposal with all assumptions and information, data, bar chart schedules, list of construction equipment and manpower to be deployed along with write-up to indicate how he intends to execute the work with stipulated time schedule. This shall form part of the tender.

(b) Time is the essence of the contract. The Contractor shall submit Daily & Monthly

Progress report. The report shall include minimum information like; Project completion progress (planned v/s actual), Work completed during last progress period, Work planned for next progress period, construction completion status for each segment, List of major civil items like, excavation, PCC, reinforcement, structural steel, planned versus actual completed, Constrain/Concern issues, Action plan to catch up the delayed progress, strength of labour, etc.

(c) Arrangement of land and construction & maintenance of all temporary facilities,

sheds, offices, labour colonies, staff quarters, temporary roads, services, fabrication yard, stores, quality control laboratory, testing laboratory, etc. required for completing the proposed scope of work shall be constructed by Contractor at his own cost.

(d) The Contractor shall have at the site accredited and qualified engineers and foremen

/ supervisors with adequate number of years of experience in execution of similar

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works and also operators of machinery and equipment, for satisfactory progress and timely completion of the works

(e) The Contractor shall submit the job procedure to the Owner and get it approved

before starting the work. (f) Contractor shall take utmost care in carrying out the concreting work. However, in

case of any patch work / rectification required in reinforced concrete work after stripping off the formwork, the same work shall be carried out immediately after stripping off the formwork, by Contractor at his own cost.

(g) The Contractor shall be responsible for housekeeping at site, during execution of

work. After completion of the work the Contractor shall remove all left out construction items, temporary constructions, etc at his own cost and clean & clear the site before handing over to the Owner.

(h) All the construction enabling works are in the Bidders scope.

9.0 TESTS FOR MATERIAL AND WORKMANSHIP

All test reports, quality plans required for material, workmanship as desired by Engineer shall be furnished by Contractor. The quality check list for the civil and structural work is as defined in technical requirement portion. The Contractor shall submit and finalize detailed quality assurance programme within 15 days from the date of award of contract according to the requirement of this specification. This shall include setting up of a testing laboratory, arrangement of testing apparatus, etc. details of which shall be finalized during the contract.

10.0 HAUL ROADS 10.1 The Contractor shall form and maintain for the duration of the contract all necessary haul

roads for the conveyance of materials from borrow area to the construction site or to disposal area as may be required. The bidder prices entered against the items in the schedule of items shall be deemed to include cost of all necessary works associated with Haul Roads.

10.2 The Haul Roads shall be constructed and surfaced with materials from site excavations or

Borrow Pits which will permit full use during periods of wet weather. Where necessary, adequate drainage shall be provided by the contractor.

11.0 BORROW PITS

The Contractor shall formulate the detail proposal for working in borrow pits. The proposal shall be submitted to the Engineer for approval, and his approval is to be obtained before the start of any work in borrow area.

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The Contractor shall divert all surface water from the vicinity of borrow pits before commencing work and shall operate borrow pits in such a manner as to be self-draining. Under no circumstances shall, material that has been exposed to standing or running water, be used in the works. All batters to excavation shall be cut to stable slopes. All organic soil shall be stripped off the area as the work proceeds and shall be temporarily stockpiled for re-use or disposal of unsuitable materials as directed by the Engineer. All unsuitable materials shall be removed and set aside in spoil heaps as approved by the Engineer. Unsuitable materials shall be defined as:-

a) Top Soil b) Organic clays, perts, logs, stumps, perishable materials and materials

suitable to spontaneous combustion. c) All materials not classified as suitable fill material. d) Any other material deemed unsuitable by the Engineer. Borrow materials shall be dug from a steeply inclined face and shall be loaded and delivered to the placing point directly so as to maintain the appropriate moisture content and to keep rejected material, unsuitable for use in the embankment, to a minimum. Where required, material shall be selected, and wherever the exposed face is of variable consistence, unsuitable material shall be discarded. Certain tests shall be carried out on samples of materials taken from borrow area under the direction of the Engineer. The Contractor shall not incorporate in the works material which has not been passed as satisfactory by the Engineer. Selection or mixing of materials may be required as directed by the Engineer. The method of excavation shall be altered as may be necessary to facilitate the selection or mixing of materials and prevent mixing of unsuitable materials with suitable materials or mixing of different kinds of materials, except as directed by the Engineer. After the excavations in borrow pits has been finally discontinued, the Contractor shall leave the borrow pit in safe condition, to the approval of the Engineer.

12.0 PREVENTION OF POLLUTION 12.1 Arrangement shall be made by the Contractor to prevent pollution of the water in any

streams, springs, nallahs and lakes. Arrangements for sprinkling of water in construction and borrow area to prevent any dust blowing also shall be done by the Contractor. The Contractor shall be solely responsible and liable for all damage caused by any pollution that may take place during the execution of works, and he shall make arrangements, as

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the Engineer may approve for preventing pollution but, notwithstanding such approval, the entire responsibility for any pollution shall rest with the Contractor.

12.2 No separate payment shall be made for the pollution control measures and the quoted

rates shall include the cost of all pollution control measures. 13.0 SAFETY MEASURES

The Contractor shall ensure the safety of men, material and structure during execution of the contract as per applicable norms and standards. Safety measures shall be followed during operations of equipment/machinery being used. No separate payment shall be made for the safety measures and the quoted rates shall include the cost of all safety measures.

14.0 EQUIPMENTS AND MACHINERY

The Contractor shall have to use his own earth moving Equipment such as dumpers, poclains, dozers etc. and any other machinery required for the entire scope of work including the work of excavation and conveyance of earth from Main Plant area or borrow areas to embankment and also shall have to use his own construction machineries such as vibratory rollers / pneumatic rubber type rollers, sheep foot rollers, slope compactors, water tankers etc. to compact the fill materials.

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ANNEXURE – I: SCHEDULE OF ITEMS FOR ASH POND DIVIDE BUND

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Rev: P0 (Draft)


(Rs) (Rs) I-1 EXCAVATION AND FILLING

1.

Earthwork in excavation upto 2.5 m depth below existing ground level for foundations, trenches,pipe lines, storm water drains etc. including lifting, dressing of sides and ramming of bottom,shoring, strutting, dewatering, stacking of excavated soil dewatering with all equipment andmaterials complete as per specification, drawings and instructions of the Purchaser / Engineer,including a lead upto 500 m within plant boundary for all types of Soil, Weathered rock and Hardrock.

a) In all types of soil /Fly Ash Cu m 47,474 b) In Weathered / Soft rock Cu mc) In Hard rock Cu m

2. Disposal of all types of surplus excavated earth within/outside plant boundary etc. all complete asper specification, drawing and instructions of the Purchaser / Engineer.a) Carriage beyond initial leads of 500 m and upto 2 km within plant boundary. Cu m 1,500 b) Carriage beyond the plant boundary upto 5 km. Cu m

3.

a) Filling using either locally available suitable earth or "fly ash in layers not exceeding 225mmloose thickness (compacted to 150 mm ) including lead upto 1 km and all lifts and includingloading from stock pile, carting, unloading, filling, watering and compacting each layer etc. allcomplete as per specification, drawings and as directed by the Purchaser / Engineer.

i) Compaction to 95% of modified proctor density or 80% of relative density Cu m 62,809 ii) Compaction to 95 % standard proctor density or 70% of relative density Cu m

b) Filling/providing and laying earthen embankment using selected excavated borrowed earth(SC, CL, CI, CI-CL, ML-CL, ML or GC in layers not exceeding 225mm loose thickness(compacted to 150 mm ) including average lead up to 2.5 Km and all lifts and including cost of allmaterials, labor and all operations such as excavation, sorting, loading from stock pile, carting,unloading, filling, watering and compacting each layer, dewatering etc. all complete as perspecification, drawings and as directed by the Purchaser / Engineer.

i) Compaction to 95% of modified proctor density (heavy compaction). Cu m 95,846 ii) Compaction to 95 % standard proctor density (Standard effort). Cu miii) With CNS ( Cohesive Non- Swelling ) material as per specifications and compacting to 95% of modified proctor density

Cu m

c) Providing and filling the cut off trench and / or Central Core (if required) with impervioussoil (either natural inorganic, low to intermediate plastic fine soil (non-expansive) or prepared soilmixed with bentonite or approved equivalent (not less than 2 per cent by volume) to achieve apermeability less than 1 x 10-6 cm / sec) in layers of 250 to 300 mm loose thickness including costof all materials, machinery and labour all operations, such as excavation, sorting, transportation,loading, unloading, dozing to the required depth, breaking the clods, sectioning, watering andcompacting to the required density using rollers of 8 to 10 MT capacity with all leads notexceeding 5 km within plant area, all lifts, dewatering, desilting etc., complete as per detailedspecifications.

i) Compaction to 95% of modified proctor density (heavy compaction). Cu m 6,319 ii) Compaction to 95 % standard proctor density (Standard effort). Cu m

4.

Providing & constructing rock-toe using clean, hard and selected rubble including filling withchips and wedging for face works including all operations such as quarrying, loading,transportation, unloading, placing, packing, finishing the top and sides to required slopes includingdesilting, cost of all materials, machinery, labour etc., all complete as per specification, drawingsand instruction of the Purchaser / Engineer.

i) Aggregate Size 100 to 350 mm Cu m 3,725 ii) Aggregate Size 40 to 80 mm Cu m 2,789

5. Lowering of Ground water table by Deep Dewatering / Well point dewatering method all completeto maintain dry working condition in foundation pits till all construction and backfilling activitiesetc. are complete

Hours

I-2 FORMWORK

6.

Supplying and fixing formwork of approved quality for cast-in-situ, plain or reinforced concreteworks of any type and section (including curved surfaces) at all elevations, including labour,materials, equipment, shoring, strutting, scaffolding, staging, tieing, nailing, caulking, bolting,testing, etc., and removal of formwork and staging, design and preparation of working drawings ofscaffolding and support structures etc. all complete as per specification, drawings and instructionsof the Purchaser / Engineer.

a) For works below ground leveli) Ordinary formwork Sq m 1,000 ii) Plywood formwork Sq mb) For works above ground leveli) Ordinary formwork Sq mii) Plywood formwork. (Film Faced) Sq m

I-3 REINFORCEMENT

7

Supplying and placing reinforcement, in reinforced concrete and allied works, at all levels,including transportation, cleaning, straightening, cutting, bending, binding in position withannealed wire and/or welding, Supplying concrete cover blocks, pins, separators, chairs, supportsfor reinforcement, etc., with all materials, labour, equipment, handling, transporting, testing etc.,preparation of bar bending drawings and schedules all complete as per specifications, designdrawings and instructions of the Purchaser / Engineer.

a) For works below ground leveli) Mild Steel reinforcement MTii) High yield strength deformed bars (Fe 415 / Fe 500) / TMT bars MT 5 b) For works above ground leveli) Mild Steel reinforcement MTii) High yield strength deformed bars (Fe 415 / Fe 500) / TMT bars MTc) Reinforcement for RCC panel above HDPE liner (Fe 415 / Fe 500) / TMT bars MT

Description of Items Unit Qty.




Rev: P0 (Draft)


(Rs) (Rs) Description of Items Unit Qty.

I-4 CONCRETING

8

Supplying and laying Nominal Mix Plain Cement Concrete using graded aggregate at all levels forall kinds of work like mass concrete, bed blocks, lean concrete, mud mat, filling, etc. includinglabour, materials, equipment, handling, transporting, batching, curing, testing, etc. all complete asper specification, drawings and instructions of the Purchaser / Engineer but excluding shutteringwork.

a) 1:5:10 (with 40mm down size grading) Cu m NAb) 1:4:8 (with 20mm down size grading) Cu m 50 c) 1:3:6 (with 40mm nominal size graded aggregate). Cu m NAd) 1:2:4 (with 20mm down size grading) Cu m NAe) 1:1.5:3 (with 20mm down size grading) Cu m NA

9

Supplying and laying Design Mix Cement Concrete for reinforced concrete work at all levels forall kinds of work, including labour, materials, equipment, handling, transporting, batching, mixing,controlling temperature, placing, levelling, compacting, curing, testing, etc. all complete as perspecification, drawings and instructions of the Purchaser / Engineer, but excluding centering,shuttering and reinforcement work.

a) For works below ground leveli) M-20 (with 20mm nominal size graded stone aggregate). Cu m NAii) M-25 (20mm nominal size graded stone aggregate). Cu m NAiii) M-30 (Temperature controlled concrete with admixture and 20mm nominal size gradedstone aggregate).

Cu m NA

iv) M-35 (Temperature controlled concrete with admixture and 20mm nominal size gradedstone aggregate).

Cu m NA

b) For works above ground leveli) M-20 (with 20mm nominal size graded stone aggregate). Cu m NAii) M-25 (with 20mm nominal size graded stone aggregate). Cu m 100

I-5 BRICK MASONRY AND ALLIED WORKS NA

10

a) Supplying and laying in position clay / fly ash brick masonry works with minimum crushingstrength of 75 kg/cm2 in cement-sand mortar 1:6 (1 Cement: 6 Sand) including mixing mortar,laying bricks, raking out joints, scaffolding, curing complete as per specification, drawings andinstructions of the Purchaser / Engineer.a) 230thk Cu m 1,058

I-6 PLASTERING AND ALLIED WORKS NA

11

Supplying 15mm thick cement plaster in single layer on all types of concrete surface or fair side ofmasonry, for all types of work, for all elevations, including scaffolding, surface preparation,mixing, application, finishing, curing, testing etc., complete with all materials, handling labour,tools and plants, etc.all complete as per specification, drawings and instructions of the Purchaser /Engineer for the following mix proportions. :

a) Cement mortar 1:4 (1 cement : 4 sand) Sq m 3,150 b) Cement mortar 1:5 (1 cement : 5 sand) Sq mc) Cement mortar 1:6 (1 cement : 6 sand) Sq md) Cement mortar 1:4 (1 cement : 4 sand) with neat cement finish Sq m

I-7 U/S and D/S Slope Protection measures and Drains

12Providing, loading, transporting, unloading, laying all materials, labour etc., and including placing, jointing HDPE liner for upstream slope and reservoir floor as per ASTM requirements.

a) 600 micron thk. Sq m 22,617 b) 750 micron thk Sq mc) 1mm thk Sq m

13

Providing & laying 150 mm thk cushion material (below HPDE lining in embankment slope and reservoir floor), as per drawings, including cost of all materials, machinery and labour all operations such as quarrying, loading, transportation, unloading, screening, placing in the required layer using formwork, watering and compacting to the required density using vibrators with all leads and lifts etc., complete as per specifications.

- Graded natural sand (D15<=0.7mm) Cu.m- Ash / bottom ash Cu.m 22,617 - Low permeable soil as Cushion material Cu.m NA

14 a) Providing & laying sand filter of approved quality at embankment sand chimney, blanket (horizontal drain) and Rock Toe including trench cutting, screening, washing, watering, compaction, dressing, necessary trimming if any including all leads and lifts etc, all complete as per specifications.

Cu.m 4,572

15

Providing, and laying bick on edge pitching over HDPE Liner including with 100 mm thick bottom ash including supply of material, moulding, formwork, wiremesh, batching, mixing, laying, compacting, curing, handling, storing, transporting, all leads, erection without damage; filling the gaps between adjacent units with concrete or grout. (a ) Using Fly ash bricks Sq m 20744

16Providing, loading, transporting, unloading, laying all materials, labour etc., and including placing, jointing/ overlapping 1.5 mm thick non-woven geotextile filter for rock toe and draiange as per ASTM requirements.

Sq m 12586

TOTAL AMOUNT IN WORDS: ______________________________________________________________

SIGNATURE OF THE BIDDER: ______________________________________

DATE: __________________

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ANNEXURE – II: DETAILED TECHNICAL SPECIFICATIONS

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SECTION 1

TECHNICAL SPECIFICATION FOR EXCAVATION AND FILLING

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CONTENTS

1.1.0 INTENT 3

1.2.0 GENERAL REQUIREMENTS 4

1.3.0 CODES AND STANDARDS 5

1.4.0 TECHNICAL REQUIREMENT- EXECUTION 6

1.5.0 SAMPLING TESTING AND QUALITY CONTROL 19

1.6.0 RATES AND MEASUREMENTS 23

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1.1.0 INTENT

i) This section of the specification covers the technical requirements of excavation and filling for embankment construction including filling for pipes, foundations, trenches, pits, drains, channels, cable ducts, underground facilities. It also covers filling areas and plinths with selected materials, conveyance and disposal of surplus spoils and / or stacking them properly as directed by the Engineer.

ii) This section covers the technical requirements of CNS (Cohesive Non-Swelling)

material filling in the cut off trench and in specified zones of the embankment and around pipes, foundations, trenches, pits, drains, channels, cable ducts, underground facilities and similar works. It also covers filling areas and plinths with CNS materials, conveyance and disposal of surplus spoils and / or stacking them properly as directed by the Engineer / Purchaser.

iii) The Contractor shall be fully responsible for proper setting out of works, profiling

in excavation, stacking of material. It shall be the responsibility of the Contractor to make adequate safety measures at the site. The Contractor shall carry out all necessary works meant within the specification, even if not explicitly mentioned herein. All works shall be executed to the satisfaction of the Engineer.

iv) The Contractor shall take all necessary precaution so as not to damage or endanger

any property, structures, roads, installation or services in the vicinity of the area. It shall be the responsibility of the Contractor, to take all necessary measures to protect existing facilities, trees or any other structures within or adjacent to the works being carried out which are not to be disturbed. The Contractor shall provide and install suitable safeguards approved by the Engineer for this purpose.

v) The Contractor shall make all necessary and adequate measure during the progress

of work against soil erosion, water and environmental pollution. It shall be the responsibility of the Contractor to undertake any additional work necessary to achieve this objective at no additional cost to the Engineer/Purchaser.

vi) The Contractor shall take prior approval from the Engineer about his work plan and

the procedure he intends to follow for the works covered under the scope of this specification and the schedule for carrying out temporary and permanent control works. However, the approval of such plans and procedures shall not relieve the Contractor of his responsibility for safe and sound work.

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1.2.0 GENERAL REQUIREMENTS

i) Prior to beginning excavation and filling work, a contract or permit shall be obtained from the Engineer/Purchaser.

ii) The Contractor shall make arrangements to perform surveying activities in locating

coordinates and establishing reduced levels. The Engineer/Purchaser shall furnish the Contractor with two reference grid lines and one Benchmark. The Contractor shall make necessary arrangement for all the survey instrument along with qualified surveyor to the satisfaction of the Engineer, so that work can be carried out accurately and according to the specification and drawings.

iii) The Contractor shall furnish all skilled and unskilled labour, plant, tools, tackles,

equipment, men, materials, required for complete execution of the work in accordance with the statutory labour regulation, drawings and as described herein and / or as directed by the Engineer.

iv) The plot boundaries shall be marked using stakes or lath with coloured plastic

flagging. The lath shall be placed at sufficient interval to enable work crews and the Engineer/Purchaser to identify the boundaries of excavation / filling.

v) The Contractor shall make all necessary and adequate measures to prevent water

from the site of his operation from causing nuisance on or in any adjacent areas /sites and neighboring property. The Contractor shall construct wherever necessary temporary drainage or other siltation prevention structures to prevent surface water from running into the excavated areas during construction. It shall be responsibility of the Contractor to properly slope the surface of the ground to the satisfaction of the Engineer.

vi) The materials obtained from within the plot area as a result of excavation or any

previously unrecorded services or other objects discovered during excavation shall be notified to the Engineer/Purchaser. Any material of archaeological importance or of value (in the opinion of the Engineer) discovered during excavation shall be stacked separately and in a regular manner at locations identified by the Engineer.

vii) It shall be responsibility of the Contractor to locate existing utilities and services if

any at the locations within the work premises by contacting local authorities. Any information available with the Engineer/Purchaser shall be made available to the Contractor on request. The Contractor shall take every preventive measure, including provision of all necessary temporary supporting, bridging, and shoring and safety barriers, to protect these services and facilities from damage or interference during the execution of the works. The stability of existing above ground and under ground services shall be maintained during the work.

viii) Excavation shall include removal of vegetation, grass, bushes, shrubs, plants, poles,

fences, etc. that are in the area to be excavated as well as beyond the excavation line so as to ensure safety of the excavated side slopes, and of men and equipment

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operating in the area. Before start of work, joint measurements of ground level shall be taken after clearing all grass, vegetation etc.

ix) Excavation shall include the removal of all materials required to execute the work properly and shall be made with sufficient clearance as decided by the Engineer or defined by payment line to permit the placing and setting of forms, inspection and completion of all works to the satisfaction of the Engineer for which the excavation was done.

x) The Contractor shall perform the work as per the drawings, issued to him and / or

Contractor’s drawings, which are approved by the Engineer and / or the Engineer’s instruction.

xi) All materials required for the work shall be of best commercial variety and

approved by the Engineer. Borrow material required for filling shall be excavated from approved locations and levels and shall consist of material, free from roots, vegetation, decayed organic matter, harmful salts and chemicals, free from lumps and clods. If specified, clean graded sand, free from harmful and deleterious material from approved quarries, shall be used as fill material.

xii) The Contractor shall carry out the proposed work in smooth cordial manner with

Contractors of other on going works in the plant. xiii) Wherever reference is made to ‘drawings’ in this specification it shall mean the

latest issue of the ‘Released for Construction’ drawings. 1.3.0 CODES AND STANDARDS

i) All standards, specifications, acts, and codes of practice referred to herein shall be the latest editions including all applicable official amendments and revisions.

ii) In case of conflict between this specification and those (IS standards, codes etc.)

referred to herein, the former shall prevail. In case any particular aspect of work is not covered specifically by this specification and IS Codes, any other standard practice as may be specified by the Engineer, shall be followed.

iii) Some of the relevant Indian Standards, Acts and Codes referred are given below:

IS:383 Specification for coarse and fine aggregates from natural sources for

concrete.

IS:1037 Code of practice for field control of moisture and compaction of soils for embankment and sub-grade.

IS:1200 Method of Measurement of building and civil engineering work

earthwork (Part-I).

IS:2720 Methods of test for soils -Determination of water content etc. (Part-II, IV to VIII, XIV, XXI, XXIII, XXIV, XXVII to XXIX, XL)

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IS:3764 Safety code for excavation work. IS:4081 Safety code for blasting and related drilling operations.

IS:4701 Code of practice for earthwork on canals. IA:6922 Criteria for safety and design of structures subject to underground IS:9758 Guide lines for Dewatering during construction. IS:14690 Quality control during construction of earth and rockfill dams –

recommendations.

1.4.0 TECHNICAL REQUIREMENT- EXECUTION 1.4.1 EXCAVATION & CLASSIFICATION

The excavation shall be carried out as per the approved proposal. The work shall be carried out without endangering the safety of nearby structure and without causing hindrance to other activities in the area. As the excavation reaches the required dimensions, lines, levels and grades, the Engineer shall be notified, so as to avoid any over excavation. In certain cases, where deterioration of the ground, upheaval, slips, etc., are expected, the Engineer may order to suspend the work at any stage and instruct the Contractor to carry out the balance work later. No extra will be paid to the Contractor for such unavoidable temporary suspension of work.

For purposes of work to be executed in accordance with this specification, the following classification only, shall apply. In case of any dispute regarding classification of materials excavated / filled, the decision of the Engineer shall be final and binding on the Contractor.

1.4.1.1 Soil / Rock shall be classified as follows;

A) Soil

Earth excavation shall consist of removal of all material encountered which can be excavated by pick axes or spades or earth moving equipment such as shovels, draglines, etc. and which are not classified under rock as defined in specification. Earth excavation shall include, but shall not be limited to, vegetation or organic soil, turf, sand, silt, mud, moorum, shingle, clay, gravel, loam, macadam, peat, shale, ash, marsh, bricks, tar/bitumen surfaces, lime concrete, stone/brick masonry etc. It shall also include embedded rock, boulders having maximum diameter in any one direction not exceeding 300 mm.

B) Disintegrated / Weathered Rock (not requiring blasting, wedging or similar means)

This may be quarried or split with crow bars or pick axes such as lime stone, sand stone, hard laterite, hard conglomerate and unreinforced cement concrete below

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ground level. It shall also include rock, which is normally hard requiring blasting when dry, but can be excavated without blasting, wedging or similar means, when wet. Soft rock excavation shall consist of the excavation of boulders, having maximum diameter in any direction or more than 300 mm lying loose on the surface or embedded in soil, and all rock in ledges, and bedded / conglomerated deposits so firmly cemented that they cannot be removed by common earthmoving tools/equipment.

C) Hard Rock

Hard rock (requiring blasting) - Any rock or boulder for the excavation of which blasting is required such as quartzite stone, granite, basalt, reinforced cement concrete (reinforcement to be cut through but not separated from concrete) below ground level etc.

Hard rock (blasting prohibited) - This shall cover any Hard rock requiring blasting as described above but where blasting is prohibited for any reason and excavation has to be carried out by chiseling, wedging or any other approved method.

In case of any dispute regarding classification, the decision of the Engineer shall be final.

1.4.2 EXCAVATION IN SOIL

i) Sides and bottoms of excavation shall be cut sharp and true to line and level. When machines are used for excavation, the last 300mm before reaching the required level shall be excavated with additional care.

ii) Excavation for ash pond divide bund or for specified area shall be to the excavation

line indicated on drawings.The bottom of all excavations shall be trimmed to required levels. For foundations, when excavation is carried below such levels, by error, it shall be brought back to specified level by filling with concrete of nominal mix 1:4:8 (cement: coarse sand: 40mm down aggregates) as directed by the Engineer at the Contractor’s cost.

iii) The Contractor shall ascertain for himself the nature of materials to be excavated

and the difficulties, if any, likely to be encountered in executing this work. Cofferdams, sheeting, shoring, bracing, maintaining suitable slopes, draining etc. shall be provided and installed by the Contractor at no extra cost, unless mentioned in the Schedule of Items, to the satisfaction of the Engineer.

iv) All excavation for installation of underground facilities, such as piping, cable duct,

sewer lines, drain lines, etc. shall be open cuts. For deep and huge excavations and in other excavations, if required by the Engineer, the Contractor shall submit an “Excavation Scheme” for Engineer's approval showing the methodology to be adopted for excavation in order to maintain the stability of side slopes, means for ensuring safety of existing facilities nearby, dewatering as described in specification. However, the Contractor shall be fully responsible for the scheme

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irrespective of any approvals granted. Benching shall be provided for deeper excavation wherever required.

v) When excavation requires bracing, sheeting or shoring etc., the Contractor shall

submit drawings to the Engineer, showing arrangements and details of proposal installation. The Contractor shall also furnish all supporting calculations as called for and shall not proceed until he has received written approval from the Engineer. However, the responsibility for adequacy of such bracing, sheeting, shoring etc., will rest with the Contractor, irrespective of any approval of the Engineer.

vi) The Contractor shall have to constantly pump out any water collected in excavated

pits and other areas due to rain water, seepage, springs etc. and maintain dry working conditions at all times until the excavation, placement of reinforcement, shuttering, concreting, back filling is completed. For the purpose of keeping the area dry through dewatering process, additional sumps as required as per site condition are to be made/excavated by the Contractor. The Contractor shall remove all slush/muck from the excavated areas to keep the work area dry. Sludge pumps, if required, shall be employed by the Contractor for this purpose.

vii) The Contractor shall remove all materials arising from excavations from the

vicinity of the work either for direct filling, stacking and subsequent filling or for ultimate disposal as directed by the Engineer. In no case, shall the excavated soil be stacked within a distance of 3.0m from the edge of excavation or one-third the depth of excavation whichever is more. Material to be used for filling shall be kept separately.

viii) Excavated material shall be used for fill unless it is classified as unsatisfactory.

1.4.3 EXCAVATION IN DISINTEGRATED / WEATHERED ROCK

i) All clauses of 1.4.2 shall be applicable to excavation in disintegrated / weathered rock also. In case of any discrepancy between the above mentioned clause and those specified in this clause then the later shall govern.

ii) The Contractor shall arrange for excavating such rock by profusely wetting it. If

required, light blasting may be resorted to for loosening the materials at Contractor’s cost, but this will not entitle the material to be classified as Hard rock.

iii) In case of overbreaks in rock excavation, the excavated level shall be brought to the

level shown on drawings with plain cement concrete of nominal mix 1:4:8 as described in clause no. 1.4.2 (ii)

1.4.4 EXCAVATION IN HARD ROCK

All clauses of 1.4.2 shall be applicable to excavation in rock also. In case of any discrepancy between the above mentioned clause and those specified in this clause then the later shall govern.

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In case of overbreaks in rock excavation, the excavated level shall be brought to the level shown on drawings with approved fill material, compacted.

1.4.4.1 Excavation by Blasting :

i) Blasting shall be carried out only with the written permission of the Engineer. All the statutory laws, (Explosives Act etc.) rule, regulations, Indian Standards, etc. pertaining to the acquisition, transport, storage, handling and use of explosives, etc. shall be strictly followed. All the blasting shall be carried out by approved experts.

ii) The Contractor shall obtain Licenses from Competent Authorities for undertaking

blasting work as well as for procuring, transporting to site and storing the explosives as per Explosives Act. The Contractor shall be responsible for the safe transport, use, custody and proper accounting of the explosive materials.

iii) The Contractor may adopt any method of blasting as permitted according to

explosives act/rule consistent with the safety and job requirements (after approval from the Engineer) and so as not to injure men or damage materials/structures during blasting operations.

iv) The magazine for the storage of explosives shall be built by the Contractor to the designs and specifications of the Explosives Department concerned and located at the approved site. No unauthorized person shall be admitted into the magazine which, when not in use, shall be kept securely locked. No matches or inflammable material shall be allowed within 100 m of the magazine. The magazine shall have an effective lightning conductor and the following shall be hung in the lobby of the magazine.

A copy of the relevant rules regarding safe storage, both in English and in the language(s) with which the workers concerned is familiar.

A statement of up to date stock in the magazine

A certificate showing the last date of testing of the lightning conductor.

A notice stating that smoking is strictly prohibited

v) The Contractor shall also observe any specific instructions given by the Engineers. The Contractor shall be responsible and liable for damage to property and any accident which may occur to workmen or to the storage, transportation, handling or use of explosive and the blasting operations. The Engineer or his authorised representative shall frequently check the Contractor’s compliance with these precautions and the manner of storing and accounting of explosives. The Contractor shall provide necessary facilities for such inspection.

vi) All materials, tools and equipment used for blasting operations shall be of approved

make and type. In special cases, the Engineer may specify the type of explosives to be allowed. The fuse to be used in wet locations shall be sufficiently water resistant so as to be unaffected when immersed in water for 30 minutes. The rate

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of burning of the fuse shall be uniform and precisely known to permit evaluation of the distance to which the firer should move before explosion takes place.

vii) The blasting powder, explosives, detonators, fuses etc. shall be fresh and not

damaged due to dampness or any other cause. Explosives shall be kept dry and shall not be exposed to direct rays of the sun or be stored in the vicinity of fire, stoves, steam pipes or heated metal etc. They shall be inspected before use and damaged articles shall be discharged totally and removed from site immediately.

1.4.4.2 Blasting Operations :

i) The blasting operations shall remain in the charge of a responsible, competent, authorised and experienced supervisor (called Man-in-Charge) and workmen who are thoroughly acquainted with the details of handling explosives and blasting operations and with the rules governing such work.

ii) All rules under the Explosives Act and other local rules in force shall be fully

observed. All blasting works shall be done in accordance with the stipulations contained in IS 4081. Blasting shall only be carried out at certain specified times preferably during the mid-day lunch time or at the days work closing hours as directed in writing by the Engineer. The hours when blasting will be done, shall be made known to people in the vicinity. All the charges shall be prepared by the Man-in-Charge (as described above) only. Proper precautions for safety of persons and property shall be taken.

iii) Prior to blasting, red danger flags shall be displayed prominently around the area to

be blasted and shall be kept in position until blasting work is completed. All people, except those who actually light the fuses, shall be prohibited from entering this area. The flags shall be planted 200 m from the blasting site and all persons including workmen shall be evacuated from the flagged area atleast 10 minutes before the firing. A warning whistle shall be sounded for this purpose.

iv) Controlled blasting shall be carried out within 200 m of an existing structure unless

otherwise permitted by the Engineer in writing. Where (generally within plant area) controlled blasting is to be carried out in the proximity of other structures, then sand bags and/or earth bags, etc. shall be used on top of the blast holes to prevent the rock fragments from causing damage to adjacent structures and property. At all stages of blasting operations, precautions shall be taken to preserve the rock in the soundest possible condition below and beyond the lines specified for the excavation. The quantity and strength of explosives used shall be such as will neither damage nor crack the rock outside the limits of excavations. Any method of blasting which leads to overshooting shall be discontinued.

v) No explosive shall be brought near the work in excess of the quantity required for a

particular amount of firing to be done and surplus left after filling holes shall be removed to the magazine. A careful and day to day account of the explosives shall be maintained by the Contractor in an approved manner and in an identified register; which shall be open to inspection by the Engineer at all times.

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vi) At a time not more than ten such charges shall be prepared and fired. The Man-in-

Charge shall blow the whistle in a recognized manner for cautioning the people. The number of blasts to be fired and actual number of shots heard shall be compared and the person responsible shall satisfy himself by examination that all blasts have exploded before any person working in the area is permitted to re-approach the work site. Sufficient time shall be allowed to account for delayed blasts. The Man-in-Charge shall inspect all the charges before lighting and determine the missed charge. The withdrawal of the unexploded charge shall not be permitted under any circumstances. After tamping, the unexploded charge shall be flooded with water and the hole marked in a distinguishable manner. Another hole shall be jumped at a distance of 450 mm from the old hole and fired in the usual way. This process shall be continued till the original blast is exploded. The Man-in-Charge shall at once report to the Contractor’s office and the Engineer, all cases of misfire, the cause for the same and what steps where taken in connection therewith.

vii) If a misfire is found to be due to defective materials, the whole quantity in the box,

from which the defective materials was taken, must be sent to the Authority directed by the Engineer for inspection to ascertain whether any of the remaining materials in the box are also defective.

1.4.4.3 Chiseling / Wedging

Where blasting is prohibited for any reason or it is not practicable in opinion of the Engineer, then the excavation shall be carried out by chiseling, wedging or any other approved method. The decision of the Engineer in this regard shall be final and binding on the Contractor.

1.4.4.4 Line Drilling and Preshearing

i) This shall be carried out only if so specified or called for by the Engineer. It is generally called for only when excavation in rock has to be carried out to exact lines and levels and when absolutely no over-excavation is permissible. It may also be required when rock excavation has to be carried out in close proximity of existing structures / equipment.

ii) The number, size and location of holes shall be carefully worked out by the

Contractor and shall be subject to the approval of the Engineer. Line drilled holes shall generally be 48 mm diameter and, if so directed, interior blasting holes shall also be made. The Contractor shall carry out tests to determine the amount of explosives required ensuring an even break at the line drilled holes. After the interior holes are blasted any irregularities in the vertical drilled line face shall be removed and trimmed by wedging, splitting, chiseling and baring.

1.4.5 DEWATERING & EXCAVATION BELOW GROUND WATER TABLE

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i) All excavations shall be kept free of water and slush. Grading in the vicinity of excavations shall be controlled to prevent surface water running into excavated areas. The Contractor shall remove by pumping or other means approved by the Engineer any water inclusive of rainwater and subsoil water accumulated in excavation and keeps the excavation area dewatered until excavation, concreting, curing and all other operation included in the scope of work, which require dry condition in the area are completed. Method of pumping shall be approved by the Engineer but in any case, the pumping arrangement shall be such that there shall be no movement of subsoil or blowing in due to differential head of water during pumping.

ii) Wherever ground water table is met with during excavation, the Contractor shall

immediately report this fact to the Engineer who shall arrange to record the exact level of the water table before start of dewatering operation. The decision of the Engineer regarding ground water level shall be final and payable provided the Contractor has made arrangement for its dewatering. For this purpose, Contractor shall submit de-watering scheme to the Engineer before starting the excavation.

iii) In case of ground water table is met with during excavation and approved by the

Engineer, the Contractor shall dewater and maintain dry working conditions by maintaining the water table below the bottom of the excavation level by well-point dewatering or deep well dewatering or any other method approved by the Engineer. He shall continue doing so till excavation and all other operations included in the scope of work, which require dry condition in the area are completed.

1.4.6 LIFT

The Contractor is required to excavate upto any depth as shown on the drawings or as directed by the Engineer. Lifting of excavated materials shall be done either by manual or mechanical or both means if called for by the Engineer.

1.4.7 CARRIAGE OF EXCAVATED MATERIALS

i) All suitable excavated material shall be directly utilized for filling purposes. In case the excavated materials are to be used for future filling purposes or found unsuitable for filling, they shall be stacked / stockpiled / disposed as directed by the Engineer. The carriage of excavated materials shall be done by the methods mentioned below:

ii) The excavated materials shall be carried beyond the working area but upto 500 m

manually or by mechanical means as directed by the Engineer.

iii) For carriage exceeding 500 m and upto 2000m, the Contractor shall transport the excavated materials by mechanical means only and as directed by the Engineer. The Contractor shall arrange for temporary access roads for this purpose. Providing and maintaining of the access roads shall be the responsibility of the Contractor.

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Some excavated materials required for filling purposes, may have to be carried upto a lead of 500 m and stacked as per instructions of the Engineer. Excavated materials carried beyond 500 m shall be for direct filling or for disposal purpose. Double handling of materials shall be avoided as far as possible. However, depending on site conditions, excavated materials carried beyond a lead of 500 m may also be required to be brought back for filling purpose.

1.4.8 STOCKPILE AREA 1.4.8.1 Stockpile of Excavated Material

i) Stockpiling of excavated material suitable for filling purposes shall be done at the location as directed by the Engineer/Purchaser / Engineer at site.

ii) The stockpile area shall be sloped to drain properly and provided with devices to

control erosion.

iii) Stockpile of Rocks shall be done separately.

1.4.9 Disposal of Excess Satisfactory Excavated Material

Excess excavated material, which is satisfactory for use as fill material, shall be used for other fills or be placed in a designated onsite stockpile area. Material may be removed from the stockpile area at a later date and utilized / disposed off as directed by the Engineer.

1.4.10 Disposal of Unsatisfactory Material

Excavated material, which is unsatisfactory for use as fill, shall be disposed of in an offsite or in an onsite disposal area as directed by the Engineer/Purchaser / Engineer at site. Unsatisfactory material shall not be mixed with satisfactory material.

The disposal area shall be sloped to drain properly and control erosion and seeded.

1.4.11 Ground Improvement Work

If the existing engineering properties of the ground results in liquefaction, unacceptable total and/or differential settlement or bearing capacity failure, the Contractor shall carry out ground improvement work as per the recommendation in the soil investigation report, the requirement of the Engineer/Purchaser and as directed by the Engineer.

Ground improvement techniques shall be covered separately, if required, and relevant Indian Standard Codes shall also be referred.

1.4.12 FILLING 1.4.12.1 Materials

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i) The material used for filling shall consist of material approved by the Engineer and obtained directly from nearby areas where excavation work is in progress or from temporary stacks of excavated soil spoils or from borrow pits from selected areas designated by the Engineer. The material shall be free from lumps and clods, roots and vegetation, harmful salts and chemicals, organic materials etc.

ii) Materials, when used for filling purposes, shall be obtained from the excavated

materials consisting of soil, stone, sand or other inorganic materials and they shall be clean and free from shingle, organic, large roots and excessive amount of sod, lumps, concrete or any other foreign substances which could harm or impair the strength of the embankment and / or substructure in any manner. All clods shall be suitably broken to small pieces. When the materials are mostly rock boulders, the same shall be stacked properly at the designated place as directed by the Engineer. Sand used for filling shall be clean, medium grained and free from impurities. Fines less than 75 microns shall not be more than 15% in any case and the materials to be used for filling purposes shall have the prior written approval of the Engineer.

iii) Borrow materials, when used, shall be obtained from approved quarries and shall

conform to the specification mentioned elsewhere. Acceptable granular materials are soils, which are classified as coarse-grained soils in the Indian Standard Soil Classification System, IS: 1498 - 1970. Classifications are GW, GP, GM, GC, SW, SP, SM or SC, or combinations of these such as SP-SC.

iv) Cohesive material is suitable for use as Fill if it contains not more than 1 percent

organic or other deleterious material, has a liquid limit of less than 40 and a plasticity index of less than 25. Acceptable cohesive materials are soils which are classified as fine-grained soils in the Indian Standard Soil Classification System, IS: 1498-1970. Classification is CL.

v) Soil-rock mixtures are acceptable for use as fill if they contain a sufficient soil

matrix to prevent nesting of larger pieces and the material contains less than one percent organic or other deleterious material.

vi) It is intended to use the excavated earth from the site for filling provided the

material conforms to the soil / soil-rock mixture specification as stipulated above and approved by the Engineer. If excavated materials are to be used for filling purposes, Contractor shall select the materials from the excavation / stockpile, test, load and transport this material and execute the filling. This shall include excavation of earth which may become hard due to laying in stockyard for long period of time. However this shall not be measured under excavation.

vii) In case the materials have to be brought from pits/quarries, then it shall be the

Contractor’s responsibility for identification of such quarry, areas, obtaining approval for their use from concerned authorities, excavation/ quarrying, loading and carriage of such material, unloading and filling at such locations. The Contractor shall pay any fees, royalties etc. that may have to be paid for utilization of borrows areas.

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1.4.13 CNS (Cohesive Non-Swelling) Material For Cutoff Trench

The CNS material to be used for filling shall meet either ‘a’ or ‘b’ of the following criteria.

SL NO.

PROPERTY SPECIFICATION RANGE

a) i) Grain Size Analysis

Clay 15 - 25 % Silt 35 - 50 % Sand 30 - 40 % Gravel Less than 10 %

ii) Consistency Limits

Liquid Limit 30 - 50 % Plastic Limit 20 - 25 % Plasticity Index 10 - 25 % Shrinkage Limit 15 % and above

iii) Swelling Pressure

Swelling pressure when compacted to maximum Less than dry density corresponding to standard proctor 0.1 kg/cm2 compaction with zero initial compaction moisture constant, for no volume change condition

Swelling pressure when compacted to maximum Less than dry density

corresponding to standard proctor 0.05 kg/cm2 compaction and initial compaction moisture corresponding to optimum moisture content for no volume condition

b) CNS material with optimum percentage of clay upto 70 % shall be mixed with

sand (30 %) and lime (1- 2 %) to meet consistency limits and swelling pressure as specified above.

1.4.13.1 Material unsatisfactory for use as fill are as follows;

Soils classified as silt or organic soils in the Indian Standard Soil Classification System, IS:1498-1970. Classifications are ML, MH, PT, OL and OH.

Soil classified as high liquid clay soils in Indian Standard Soil Classification System, IS:1498-1970. Classification is CH.

Rock material without a soil matrix in which nesting of rocks could occur.

Any material, which is frozen, contains an excessive amount of organic material or trash or contains large rocks, shall be considered unsatisfactory for use as fill.

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Top soils which are friable sandy-loam suitable to sustain the growth of vegetation

Restrictions on the use of poorly graded sand (SP) or silty sand (SM) material are as follows:

No granular material with a silt content of greater than 15 percent shall be used for Fill.

1.4.13.2 Filling Procedure

i) Embankments shall be constructed to the proper alignment and grades Placement of fill material shall be performed in an orderly sequence and in an efficient and workman like manner, so as to produce fills having such qualities of density, strength and permeability as will ensure the highest practicable degree of stability and performance of the whole embankment. Top layer of entire area shall be stripped off if specified in the drawing and the depth of stripping shall be as per approved drawing. All loose surface or soft soil should be removed to about minimum 300 mm depth unless anything else is specified in drawing or schedule of item.

ii) Trimming and dressing of both upstream and downstream slopes of embankment shall be carried out to maintain required slopes while the filling and compaction work is in progress. Trimmed materials can be reused in the embankment work. Slopes shall be maintained till the final completion and acceptance of the embankment work by the Engineer-in Charge. Any material from either side of slope that is lost by weathering or any other cause shall be replaced with proper compaction. To ensure proper compaction at the outer edge, the fill shall be constructed for a minimum of 500 mm extra width on both edges and the outer edge shall be dressed to true slope after compaction.

iii) Prior to embankment filling or backfilling around foundation & other construction below the final grades, all temporary shoring, timber, etc. shall be sequentially removed and the area shall be cleaned off all trash, debris, and perishable materials. Filling shall begin only with the written approval of the Engineer. Also, areas identified for backfilling shall be cleared of all soft pockets, vegetation, bushes, slush etc. In case of plinth and similar filling, the ground shall be dressed and consolidated by ramming and light rolling.

iv) Fill materials shall not be dropped directly upon or against any structure or facility where there is danger of displacement or damage. Filling shall be started after the concrete/masonry has fully set and shall be carried out in such a manner so as not to cause any undue lateral thrust on any part of the structure.

v) Fill shall be placed in continuous horizontal layers not exceeding 225mm loose thickness (compacted thickness 150 mm). Each layer shall be watered and compacted with proper moisture content and with such equipment as may be

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required to obtain a compaction/density as specified. The methods of compaction shall be subject to the approval of the Engineer. Pushing of earth for filling shall not be adopted under any circumstances.

vi) Fill adjacent to pipes shall be free of stones, concrete, etc. and shall be hand placed and compacted uniformly on both sides of the pipe and where practicable up to a minimum depth of 300mm over the top of pipes. While tamping around the pipes, care shall be taken to avoid unequal pressure.

vii) Filling shall be accurately finished to line, slope, cross section and grade as shown on the drawings. Finished surface shall be free of irregularities and depressions and shall be within 20mm of the specified level.

viii) Where filling with stone from excavated materials is specified, it shall be from broken pieces of boulders. At first, a 75mm thick cushion of selected earth shall be laid over which the 200mm thick graded stones shall be laid in loose layers of 200mm and then the interstices filled with available earth/ moorum. Each layer shall be watered and compacted to the specified density before the next layer is laid. However, no cushion shall be required where filling is over non-rocky surface.

ix) Where filling with 65mm down graded stone obtained from excavated materials/borrow areas/quarries is specified, it shall be selected stone laid over an initial 50mm thick cushion layer of selected earth and then stone laid in 200mm loose thick layers, interstices filled with properly graded fine material consisting of selected earth brought from borrow areas. Each layer shall be watered and compacted to the specified density before the next layer is laid. However, no cushion shall be required where filling is over non-rocky surface.

x) Where clean stone fill is specified, it shall consist of clean selected stone metal of 40mm nominal size. It shall be laid in layers not exceeding 150mm (loose) and lightly tamped before the next layer is laid. No compaction shall be required for this type of stone filling unless otherwise mentioned in the drawings or schedule of item.

1.4.14 Compaction

i) Where compaction to 85% Standard Proctor Density is called for, such compaction shall be by mechanical means but the Contractor may be permitted to adopt manual means only if the Engineer finds that the desired compaction is achievable in the field.

ii) Where compaction to 85% or more of Standard Proctor Density is called for, it

shall be by mechanical means only. Where access is possible, compaction shall be by 12 Ton rollers smooth wheeled, sheep foot or wobbly wheeled as directed by the Engineer. A smaller weight roller may be permitted by the Engineer in special cases, but in any case not less than 10 passes of the roller will be accepted for each layer. Each layer shall be wetted or the material dried by aeration to moisture

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content of 3-5% above the Optimum Moisture Content, to be determined by the Contractor. Each layer shall be watered, rammed and compacted to the density as specified.

iii) For compacting each sand layer, water shall be sprayed over it to flood it and it

shall be kept flooded for 24 hours to ensure maximum compaction. Vibro-compactors shall also be used if necessary to obtain the required degree of compaction. Any temporary works required to contain sand under flooded condition shall also be undertaken. The surface of the consolidated sand shall be dressed to required levels or slope.

iv) When soils are used that develop a densely packed surface as a result of spreading

or compaction, the surface of each layer of fill shall be sufficiently roughened after compaction to ensure bond of the succeeding layer.

v) After the compacted fill has reached the desired level, the surface shall be flooded

with water for 24 hours, allowed to dry and then rammed and consolidated to avoid any settlement, at a later date. The compacted surface shall be properly shaped, trimmed and consolidated to an even gradient or level. All soft spots shall be excavated, filled and consolidated.

vi) The degree of compaction of compacted fill in place will be subject to tests to be

conducted by the Contractor and witnessed by the Engineer as the work progresses. The Contractor shall provide all the necessary facilities to make such tests. Each layer of compaction fill shall be tested before proceeding with the next layer. It shall be the responsibility of the Contractor to conduct tests to ascertain the degree of compaction of fill material in place. At the time of conducting test it shall be mandatory on the part of the Contractor to inform the Engineer. It is the Contractor’s responsibility to request inspection prior to proceeding with further work.

vii) If any test indicates that the compaction achieved is less than the specified degree

of compaction, the Engineer may advise all fill placed subsequent to the last successful test to be removed and recompacted by the Contractor. Compaction procedure shall be amended as necessary to obtain satisfactory results.

viii) When the Engineer specifies semi-compacted fill (area filling), the Contractor shall

fill up such areas with available earth from stockpiles or borrow pits or directly from excavation without special compaction except that obtained by moving trucks, etc.

1.4.15 TIMBER SHORING

Timber Shoring made out of approved quality of timber shall be ‘close’ or ‘open’ type, depending on the nature of soil and the depth of pit of trench and the type of timbering shall be determined by the Engineer. It shall be the responsibility of the Contractor to take all necessary steps to prevent the sides of trenches and pits from collapsing.

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1.4.15.1 Close Timbering

i) Close timbering shall be done by completely covering the sides of the trenches and pits generally with short, upright members called ‘polling boards’. These shall be of minimum 250x40 mm sections as directed by the Engineer. The boards shall generally be placed in position vertically in pairs, one board on each side of cutting, and shall be kept apart by horizontal walers of strong wood at maximum 1.2 metres spacing, cross strutted with ballies or as directed by the Engineer. The length of the balli struts shall depend on the width of the trench or pit.

ii) In case where the soil is very soft and loose, the boards shall be placed horizontally

against the sides of the excavation and supported by vertical walers, which shall be strutted to similar timber pieces on the opposite face of the trench or pit. The lowest board supporting the sides of the trench or pit shall remain exposed so that the vertical side of the trench or pit is exposed, and the earth is not liable to slip out.

iii) The withdrawal of the timber shall be done very carefully to prevent the collapse of

the pit of trench. It shall be started at one end and proceeded systematically to the other end. Concrete or masonry shall not be damaged during the removal of the timber. No claim shall be entertained for any timber which cannot be withdrawn and is lost or buried.

1.4.15.2 Open Timbering

In the case of open timbering, the entire surface of the side of trench pit is not required to be covered. The vertical board of minimum 250 mm width and minimum 40 mm depth shall be spaced sufficiently apart to leave unsupported strips of maximum 300 mm average width. The detailed arrangement, sizes of the timber and the distances apart shall be subject to the approval of the Engineer. In all other respects, specification for close timbering shall apply to open timbering.

1.4.15.3 Treatment of Slips

The Contractor shall take all precaution to avoid high surcharges and provide proper surface drainage to prevent flow of water over the side. These precautions along with proper slopes, berms, shoring and control of ground water should cause no slips to occur. If however slips do occur due to causes beyond the control of the Contractor, the same shall be removed by him and payment shall be made to him on appropriate item rate of earthwork approved by the Engineer. Slips caused due to negligence of the Contractor will be cleared and back-filled later by him at his own expenses.

1.5.0 SAMPLING TESTING AND QUALITY CONTROL 1.5.1 General

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i) The Contractor shall examine the areas and conditions under which earthwork is to be done and notify the Engineer/Purchaser in writing, about the conditions detrimental to proper and timely completion of the Work.

ii) The Contractor shall carry out all sampling and testing as per Table-1 and in

accordance with the relevant Indian Standards. Where no specific testing procedure is mentioned, the tests shall be carried out as per the prevalent accepted engineering practice in concurrence of the Engineer. Tests shall be done in the field and at a laboratory approved by the Engineer and the Contractor shall submit to the Engineer, the test results in triplicate within three days after completion of a test.

iii) Material, placing procedures and installations and test conducted by the Contractor

are subject to inspection. Such inspections and tests shall not relieve Contractor of responsibility for providing material and placement in compliance with this specification. The Engineer/Purchaser reserves the right, at any time before final acceptance, to reject material not complying with the specified requirements.

iv) The Contractor shall correct all deficiencies in earthwork which inspections and

laboratory and field tests have indicated are not in compliance with this specification. The Contractor shall perform additional tests, at his expense, as may be necessary to reconfirm any noncompliance of the original work and as may be necessary to show compliance of corrected work.

v) The Contractor shall promptly correct errors or flaws in the work or material

identified during construction and which prevent proper installation. The Contractor shall make immediate substitution of the noncomplying material or shall make field changes to make the noncomplying material acceptable. The correction or substitution shall be performed at no cost to the Engineer/Purchaser.

1.5.2 Quality Assurance Program

i) The Contractor shall submit and finalize a detailed Field Quality Assurance (FQA) Program, within 30 days, from the date of award of the Contract according to the requirements of the specification. This shall include setting up of a testing laboratory, arrangement of testing apparatus/equipment, deployment of qualified/ experienced manpower, preparation of format for record, Field Quality Plan, etc. On finalising field quality plan, the Contractor shall identify hold points beyond which work shall not proceed without written approval from the Engineer.

ii) Frequencies of sampling and testing including the methods for conducting the tests

are given in Table-1. The testing frequencies set forth are the desirable minimum. Contractor shall perform additional tests as directed by the Engineer to satisfy him that the materials and works comply with the specifications.

1.5.3 Acceptance Criteria

Following Acceptance Criteria shall be followed:

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i) All individual samples collected and tested should pass without any deviation when only one set of sample is tested.

ii) For re-test of any sample, two additional samples shall be collected and tested, and

both should pass without any deviation.

iii) Where a large number of samples are tested for a particular test, then 9 samples out of every 10 consecutive samples tested shall meet the specification requirement.

iv) Tolerance on finished levels for all cutting and filling areas at approved interval

shall be 20 mm.

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TABLE –1

FREQUENCY OF SAMPLING AND TESTING

SR. NO.

Nature of Test/ Characteristic

Method of Test

No. of Samples & Frequency of Test

Results

I. Suitability of Fill Materials

a) Grain size Analysis IS:2720 (Part IV)

One in every 500 Cu.m. for each type and each source of fill material. Minimum three tests if replacement of material is required.

Test for soil and sand

b) Liquid limit and Plastic Limit

IS:2720 (Part V)

Subjected to a minimum of two samples.

Test for soil

c) Shrinkage Limit IS:2720 (Part VI)

One in every 5000 Cu.m. for each type and each source of fill materials.

The frequency of Test shall be increased depending on the type of soil.

d) Free Swell Index IS:2720 (Part XL)

e) Specific Gravity IS:2720 (Part III)


Chemical Analysis IS:2720

a) Organic matter Part XXII One in every 5000 Cu.m. for each type and each Sources of fill materials.

Test for sand and soil. b) Calcium carbonate Part XXIII

c) pH Part XXVI d) Total soluble sulphate Part XXVII

II. Standard Proctor Test

IS:2720 (Part VII)


Test for soil for determining optimum moisture content, Dry density etc.

III. Moisture content of Fill before compaction.

IS:2720 (Part II)

-do- Test for soil

IV. Degree of compaction of Fill

For area filling, one test for every 1000 Sq.m. for each compacted layer.

Test for soil

a) Dry density by core cutter method

Or

IS:2720 (Part XXIX)

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SR. NO.

Nature of Test/ Characteristic

Method of Test

No. of Samples & Frequency of Test

Results

Dry density in place by sand displacement method.

For area filling, one test for every 1000 Sq.m. area for each compacted layer.

b) Relative density (Density Index)

IS:2720 (Part XIV)

-do- i) & ii) Test for sand

c) Dry Density by Proctor needle penetration

Standard Practice

Random checks to be carried out for each compacted layer in addition to tests mentioned under IV (a) above.

Test for sand

1.6.0 RATES AND MEASUREMENTS 1.6.1 Rates

i) The item of work in the Schedule of Quantities describes the work in brief. The various items of the Schedule of Quantities shall be read in conjunction with the corresponding sections in the technical specifications including amendments and additions, if any. For each item in the Schedule of Quantities, the Contractor’s rates shall include the activities covered in the description of the item as well as all necessary operations described in the specifications.

ii) The Contractor’s quoted rates shall include all minor details which are obviously

and fairly intended and which may not have been included in the description in these documents but are essential for the satisfactory completion of the work. Quoted rates shall also include for taking all safety measures as required by Codal provisions, local regulations etc. and for execution to the satisfaction of the Engineer. Clearing all grass, vegetation etc. shall be inclusive in the rate.

iii) The Contractor’s quoted rate for each item shall be inclusive of providing all plant,

equipment, men, materials, skilled and unskilled labour, making observations, surveying/ establishing the ground level and co-ordinates at location of each work by carrying levels from one established bench mark and distances from one set of grid lines furnished by the Engineer/Purchaser.

iv) Rates shall also include for all testing, quality control requirements, arranging

inspection, etc. The rates quoted shall be all inclusive of providing temporary works, wastage, overheads, profits and all such requirement. Nothing extra shall be payable over and above the quoted rates on these accounts. Rates shall include for any additional excavation and filling for all leads and lifts, including transportation to disposal area and bringing back for refilling with proper compaction as specified, if any, beyond the payment line.

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v) No claims whatsoever shall be entertained if the detail shown on the ‘Released for

construction drawings’ differ in any way from those shown on the bid/tender drawings.

1.6.1.1 Excavation in Soil/Rock

i) It shall be assumed that the Contractor has ascertained the nature of work involved, the type of materials to be excavated, ground water and surface water conditions and conditions likely to prevail during high ground water conditions etc. No claims on these or any other accounts shall be entertained at a later date.

ii) Over excavation/ overbreaks in rock/ soil done by Contractor, shall not be

measured for payment. The quoted rate for excavation shall include making good the over excavation with 1:4:8 cement concrete.

1.6.1.2 Excavation below Ground Water table:

i) Cost of dewatering measures to be taken for dewatering of rainwater, capillary / seepage water, springs, drains, etc. and diverting of ground surface water by manual / pumping method shall be included in the basic rate of excavation.

ii) The lowering of the ground water table by well-point and/or deep well dewatering

etc. shall be paid separately under relevant schedule of item in additional to the basic rate of excavation. The rate shall include all associated works so that all the activity from excavation up to completion of filling and testing can be executed in dry working condition.

1.6.1.3 Filling:

i) Rates quoted for filling using excavated /CNS materials shall include for all lifts and lead upto 500 m. For lead exceeding 500 m, the Contractor shall be paid separately as per the instruction of the Engineer / Purchaser.

ii) In the event, filling materials to be brought from borrow pits, quarries; it shall be

the responsibility of the Contractor to identify location of borrowpits and quarries, from where filling material shall be brought to site. The quoted rate shall include cost of excavated material, testing for conformance, royalties, taxes and duties, removal/cutting of suitable materials from stock piles/borrow areas/quarries, loading, carriage upto fill area, unloading, compaction, testing etc. all complete as per specifications including all leads and lifts.

iii) Rate quoted for filling / CNS Material, filling operation shall include cost of water,

dewatering and other incidental like rolling natural ground level etc. required such that the filling can be compacted in layers to the desired degree of compaction and in the dry condition.

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iv) For stone filling, payment shall be for the compacted volume of stone filling. No separate payment shall be due for filling interstices and for the 75/50 mm thick cushion provided with selected earth.

1.6.2 Measurements:

All measurements shall be in SI units.

i) Linear measurement shall be in meters (m) correct upto second place of decimal. Areas and volumes shall be calculated from the linear measurements and shall be in square meters and cubic metes respectively, rounded off to two decimal places. For rounding off, values in the third decimal place which are below 5 shall be ignored and those 5 and above shall be taken as 10.

ii) For each item of work, the total quantity for payment at quoted rate shall be the

lesser of actual quantity executed and that evaluated on the basis of the method of measurements given herein.

iii) All measurements shall be recorded by the Contractor and duly certified/ approved

by the Engineer.

iv) The following works shall not be measured separately and allowance for the same shall be deemed to have been made in the description of main item: Setting out works, profiles, etc; Site clearance, such as cleaning grass and vegetation; Unauthorized bettering or benching of excavation; Forming (or leaving) ‘dead men’ and ‘tell tales’ in borrow pits and their

removal after measurements; Forming (or leaving) steps in sides of deep excavation and their removal after

measurements; Excavation for insertion of planking and strutting; Unless otherwise specified, removing slips or falls in excavations; Bailing out or pumping of water in excavation from rains; Slinging or supporting pipes, electric cables etc, met during excavation.

1.6.2.1 Excavation:

i) Excavation shall be measured in cubic meters. The lateral dimension for excavation

shall be the lesser of a) actual excavation outline and b) 0.3 m on each side outside concrete outline of lowest footing for depths upto 1.0m below existing grade and l.0m on each side outside concrete outline of lowest footing for depths more than l.0m below existing grade (with concrete dimensions determined from drawings).

ii) For measurement purposes the sides shall be considered vertical with the lateral

dimensions indicated above. Nothing extra would be payable for slope etc. irrespective of whatever is provided. Excavation corresponding to sloped profile of

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sides of excavation, however, shall be payable only in case they are especially called for as payable in the 'Released for construction' drawings.

iii) The limiting quantity of excavation will be evaluated based on the vertical distance

from the existing grade level to the bottom level of lean concrete as shown on drawing or actual depth excavated, whichever is less.

iv) For evaluating the quantity of excavation in rock, the Engineer shall be intimated

by the Contractor as soon as rock level is reached. The decision as to whether rock is met or not shall be that of the Engineer and his decision shall be final and binding on the Contractor. Rock levels shall be recorded jointly by the Contractor and the Engineer. Measurements for rock excavation shall be taken separately for each item of work defined under excavation in rock in the Schedule of Quantities.

v) In excavation of areas where rock & soil are mixed or large boulders requiring

blasting are met with in soil, blasted and excavated rock shall be suitably stacked separately & measured. Such measured quantum of rock shall be reduced by 30% to account for voids in stacks to arrive at quantity of rock actually excavated. Balance quantum out of total excavation shall be treated as excavation in soil.

The actual ratio of soil to rock shall be determined based on the above exercise. The measured quantities for soil and rock for payment purpose shall be arrived at following mode of measurement as per clause no 1.6.2.1 and the above ratio.

vi) Over excavation/overbreaks in soil/rock done by the Contractor, shall not be

measured for payment. Similarly the 1:4:8 mix cement concrete placed to make up the over excavation/break shall also not be measured for payment. Similarly the soil filling and compaction to make up the over excavation/break shall also not be measured for payment.

1.6.2.2 Excavation below Ground Water Table

i) The measurement for payment shall be based on volumetric calculation of soil excavated below the ground water table as approved by the Engineer.

ii) Clause no 1.6.2.1 shall also be applicable for purposes of measurement of

excavation below ground water table except that the vertical distance shall be measured below the ground water table prevailing at the location where excavation quantity is being measured.

1.6.2.3 Lift:

Lift shall be measured in meters as the vertical distance from the existing grade level to the level from which the wet/dry materials are excavated. The quantity for each range of lift shall be the quantity of materials excavated and measured as per excavation.

1.6.2.4 Carriage of Materials

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i) Lead shall be measured as the distance carried of the wet/dry materials from the centre of the area of excavation to the corresponding centre of the area of stack/fill/disposal area of this material.

ii) For purpose of calculation of lead, the excavation areas and disposal areas shall be

divided into suitable blocks/areas of maximum dimensions of 50 m x 50 m or actual area of excavation/stack/ disposal whichever is less. The distance between the centre of excavation area and corresponding stack/fill/disposal areas shall be measured along the shortest possible haulage path and not necessarily the one actually taken. The decision of the Engineer in this regard shall be final and binding on the Contractor.

iii) The quantity of materials to be considered for payment for carriage shall be least of

(a) quantity of materials actually excavated, (b) quantity of excavation payable as per mode of measurements for excavation and (c) quantity of materials actually carted considering 30% voids.

iv) For each range of lead distance given in the Schedule of Quantities, the quantities

carted are calculated separately on the basis indicated above.

v) In any specific instance, the Engineer may require filling material to be obtained from borrow areas. Only in such instances, a lead for carriage of fill materials from identified borrow areas to location of filling shall be measured for payment. In such instances, the distance of carriage to be considered for payment shall be calculated on the same basis as above except that the distance shall be measured from the centre of borrow area (subdivided plot) to the location of filling as approved by Engineer in case of initial lead.

1.6.2.5 Filling

i) Quantity of fill shall be in Cu.m of the compacted volume of fill in place calculated on the basis of ;

Levels recorded before and after filling Certified quantity of the excavation as per clause no 1.6.2.1 After deducting concrete volume etc.

ii) For stone filling, only the compacted volume of stone filling shall be measured. No

separate payment shall be due for filling interstices with soil, sand, moorum and equivalent.

iii) In any specific instance, the Engineer may require filling material to be obtained

from borrow areas. Only in such instances, fill materials from identified borrow areas shall be measured for payment.

iv) Quantity of CNS filling shall be same as per clause no 1.6.2.5 (i).

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APPENDIX - A

TECHNICAL SPECIFICATIONS FOR CONSTRUCTION OF EMBANKMENT USING FLY ASH

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A.1.0 SCOPE

Present section of specification provides salient details regarding construction of embankments using fly ash. In case of any deviations, present specifications will take precedence.

A.2.0 MATERIALS

D) Fly Ash

The following information on the Fly Ash to be used should be made available for the Engineer's approval before commencement of work: 1. Particle size of the material

2. The maximum dry density (MDD) and optimum moisture content (OMC) as per IS

Heavy Compaction test (commonly known as modified proctor test), and the graph of density plotted against moisture content, for this test.

In general, fly ash of compacted density lower than 1.1 gm/cc shall not be suitable for embankment construction. The design parameters should be rechecked, when fly ash of lower densities is encountered. To determine the following engineering properties of fly ash, tests shall be carried out in accordance with the procedures laid down in IS:2720 (Method of Tests for Soils-relevant parts): 1. Shear strength parameters, for evaluation of the stability of proposed slopes and the

bearing capacity of foundations located on the fill. 2. Compressibility characteristics, for predicting the magnitude and duration of the fill

settlement. 3. Permeability and capillarity are required to assess seepage and to design drainage

systems. To avoid the possibility of any liquefaction to occur during strong earthquake shaking, the following precautions may be taken: 1. Proper compaction of the fill material as per specifications 2. In case water table is high, it should be lowered by providing suitable drains or

capillary cut-off

3. By sandwiching ash between intermediate horizontal soil layers.

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Typical values for different geotechnical properties of fly ash to be used as reference are given in Table 1 for guidance. In general fly ashes with properties as given in Table 1 are acceptable for embankment construction. Table 1. Typical Geotechnical Properties of Fly Ash Parameter Range Specific Gravity 1.90-2.55 Plasticity Non-Plastic Maximum Dry Density (gm/cc) 1.1-1.6 Optimum Moisture Content (%) 38.0-18.0 Cohesion (kN/m2) Negligible Angle of Internal Friction () 300-400 Coefficient of Consolidation Cv (cm2/sec) 1.75x10-5 -2.01x10-3 Compression index Cc 0.05-0.4 Permeability (cm/sec) 8x10-6 – 7x10-4 Particle Size Distribution (% of materials)

Clay size fraction 1-10 Silt size fraction 8-85

Sand size fraction 7-90 Gravel size fraction 0-10

Coefficient of Uniformity 3.1-10.7

Fly ash to be used as fill material should not have soluble sulphate content exceeding 1.9 gm. (expressed as SO) per litre when tested according to BS:1377 Test 10 but using a 2:1 water-soil ratio. Otherwise, it shall not be deposited within 500 mm (or other distance prescribed by the Engineer) of concrete, cement bound materials and other cement material or metallic surface forming part of permanent works. For details, Ministry of Road Transport and Highways Specifications for Road and Bridge Works, Section 305.2 may be referred. The leaching problem of ground and surface water is to be minimized by controlling the amount of water, which infiltrates into fly ash embankment. Percolation of water into the fly ash core will be minimized by providing side and top earth cover using good earth. Further, by providing impervious wearing course to the pavement constructed over the embankment seepage can be minimized. Side slopes should be properly benched and protected with soil cover with vegetation or soil cover with stone pitching.

E) Earth Cover

The fly ash embankments should be covered on the sides and top by soil to prevent erosion of ash. Good earth suitable for embankment construction can be adopted as cover material for fly ash embankments. Gravel may be used to construct granular cut-off at the bottom. These materials are to be tested as per specifications for fill materials used in embankment construction. The soil used for cover should not have maximum dry density not less than 1.7 gm/cc when height of embankment is upto 3m and in areas

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not subjected to extensive flooding, otherwise the maximum dry density of cover soil should not be less than 1.8 gm/cc when tested according to IS:2720 (Part 8)-1983. Earthen shoulder material should have minimum compacted dry density of 1.75 gm/cc when tested according to IS: 2720 (Part 8)-1983. Plasticity index of cover soil should be between 5 to 9 per cent when tested according to IS: 2720 (Part 5)-1985. Chemical analysis or determination of deleterious constituents would be necessary in salt-infested areas or when presence of salts is suspected in the borrow material. Expansive soils should not be used for construction of cover, unless it is properly stabilised using lime.

A.3.0 TECHNICAL REQUIREMENTS A.3.1 Conformity with Designs

The contractor shall carryout the work as per the drawings issued to him and / or contractor's drawings which are approved by the Engineer and / or the Engineer's instructions.

A.3.2 Clearing and Grubbing

This work consists of cutting, removing and disposal of trees, bushes, shrubs, roots, grass, rubbish, etc., from the alignment and within the area of land which will accommodate the embankment, drains and such other areas as specified on the drawings. During clearing and grubbing, the contractor shall take adequate precautions against soil erosion, water pollution, etc. All trees, stumps, etc., falling within fill area should be cut to at least 500 mm below ground level and pits shall be filled with suitable material and compacted thoroughly so as to make the surface at these points conform to the surrounding area.

A.3.3 Stripping and Storing of Top Soil When constructing embankment using fly ash, the top soil from all areas to be covered by the embankment foundation should be stripped to specified depth not exceeding 300 mm and stored in stock piles of height not exceeding 2 m, for use in covering the fly ash embankment slopes (if soil is suitable), cut slopes and other disturbed areas where re-vegetation is desired. Top soil should not be unnecessarily trafficked either before stripping or when in stockpiles. Also, these shall not be surcharged or otherwise loaded and multiple handling should be kept to minimum.

A.3.4 Setting Out After the site has been cleared, the limits of embankment should be set out true to lines, curves, slopes, grades and sections as shown on the drawings. The limits of the embankment should be marked by fixing batter pegs on both sides at regular intervals as guides before commencing the construction. The embankment should be built sufficiently wider than the design dimensions so that surplus material may be trimmed, ensuring that the remaining material is of the desired density and in position specified,

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and conforms to the specified slopes. Bench marks and other stakes should be maintained as long as in the opinion of the engineer, they are required for the work.

A.3.5 Dewatering If the foundation of the embankment is in an area with stagnant water, and in the opinion of the Engineer it is feasible to remove it, the same should be removed by pumping or any other means as directed by the Engineer, and the area of the embankment foundation should be kept dry. Care should be taken to discharge the drained water so as not to cause damage to works, crops or any other property. Construction of embankments underwater logged conditions shall be governed by provisions of IRC: 36-1970.

A.3.6 Compacting the Ground Supporting Embankment

Where necessary, the original ground should be levelled, scarified, mixed with water and then compacted by rolling so as to achieve minimum 95 percent of MDD determined as per IS:2720 (Part 8)-1983 for the foundation soil. At locations where water table is high and the soil has potential for rapid and relatively great migration of moisture by capillarity, a granular layer, impervious membrane or a barrier of approved medium shall be inserted so that moisture is not able to rise to the subgrade level. Sand blanket of adequate thickness over full width of embankment can be adopted as an effective capillary cut-off. Medium grained sand can be used for this purpose. This will provide a working platform for the construction of fly ash fill and function as capillary cut-off. Bottom ash can also be used for construction of drainage blanket. Its grain size distribution is generally compatible with the grain size distribution of medium grained sand. Further guidance regarding capillary cut off design and its provision can be obtained from IRC: 34-1970, 'Recommendations for Road Construction in Water Logged Areas'. Where so directed by the Engineer, any unsuitable material occurring in the embankment foundation shall be removed and replaced by approved materials laid in layers, to the required degree of compaction. Any foundation treatment specified for embankment especially high embankments, resting on suspect foundations as revealed by borehole logs should be carried out in a suitable manner to the depth required. The depth of boreholes should be related to the height of embankment to be constructed and as per the direction of Engineer or Purchaser.

A.3.7 Handling and Transportation of Fly Ash Fly ash being a very fine material gets air bone easily and causes dust nuisance. Dust at a construction site may be a safety hazard. It may also lead to environmental pollution, public resentment and damage to internal combustion engine of the construction equipment besides being a health hazard to workers. To avoid this, fly ash from hoppers or silos must be conditioned with water at power plant to prevent dusting. Fly ash is typically delivered to the site in covered dump truck to minimize loss of moisture and dusting. On the other hand, pond ash generally contains enough moisture to prevent dusting, and may even contain excess moisture to create road spillage during transport.

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In such cases, periodic inspections and lifting of ash from relatively dry areas of the pond would be needed. The fly ash may require on site temporary stockpiling if the rate at which the ash is supplied to the project site is more than the contractor's demand for an efficient rate of placement. Such cases should be avoided to the extent possible, and in case stockpiling at site is inevitable, adequate precautions should be taken to prevent dusting by spraying water on stockpiles at regular intervals. Otherwise, the surface of the fly ash stockpile may be covered with tarpaulins or a thin layer of soil or other granular material not subject to dusting. Traffic movements may be restricted to those areas which are kept moist, to prevent tyres of passing vehicles dispersing ash into the air.

A.3.8 Spreading and Compaction The side soil cover of required width shall be provided along with the core and mechanically compacted as the embankment progresses upwards. The addition of side cover subsequent to the construction of the core is prohibited. The-fill material should be spread by mechanical means, finished by motor grader. The motor grader blade shall have hydraulic control so as to achieve the specified slope and grade. The most efficient lift thickness is a function of roller weight and vibratory energy. Smaller vibratory rollers with dead weights of 10 to 15 kN perform well on loose layer thickness of the order of 100-150 mm. Medium weight vibratory rollers with dead weights in the range 60-100 kN, provide satisfactory compaction for loose layer thickness of about 250 mm. When vibratory roller of dead weight 80-100 kN are used, loose layer thickness upto 400 mm can be adopted if site trials show satisfactory compaction. When compaction is carried out using only static roller of 80-100 kN weight, loose layer thickness shall not exceed 200 mm. The cover soil and fly ash should be laid simultaneously before compaction, to ensure confinement of fly ash. Clods or hard lumps in cover soil shall be broken to have a maximum size of 50 mm. Moisture content of the fill material shall be checked at the site of placement prior to commencement of compaction. Moisture content of fly ash laid for compaction shall normally vary from OMC (determined as per IS: 2720 (Part 8):1983 to OMC ± 2 per cent. The moisture content limits can be varied depending on the weather conditions, by the Engineer-in-charge, provided specified compaction is achieved as revealed through actual site trials and there is no dust problem. It may be noted that grain shape and particle size of fly ash make the upper layers difficult to compact. At moisture contents higher than the appropriate range, fly ash may liquefy and would be difficult to handle and compact. Moisture content of cover soil shall be maintained at its OMC. Where water is required to be added to the fill material, it shall be sprinkled from a water tanker fitted with a sprinkler capable of applying water uniformly without any flooding. The water shall be mixed thoroughly by blading or harrowing or by suitable means until uniform moisture content is obtained throughout the depth of the layer. If the material delivered to the construction site is too wet, it shall be dried by aeration and exposure to sun, till the moisture content is acceptable for compaction.

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Fly ash can be compacted using vibratory or static rollers. Towed or self-propelled vibratory rollers are recommended. Regardless of the equipment used, fly ash must be compacted as early as possible after spreading. The contractor shall demonstrate the efficacy of the equipment he intends to use by carrying out compaction trials. The procedure to be adopted for these site trials shall be first submitted to the Engineer for approval. The use of test strips to develop compaction method specifications (optimum compaction procedure to satisfy density requirements) for the Construction of the embankment is advisable. Each layer of fly ash shall be thoroughly compacted to the specified density. When vibratory roller is adopted for compaction, two passes without vibration followed by 5 to 8 passes with vibration would be sufficient to compact individual layers. Mass per meter width of roller is recommended to be 2300-2900 kg/m and frequency range 1800-2200 rpm. The construction of fly ash core and earth cover on the sides should proceed simultaneously. Each compacted layer shall be finished parallel to the final cross-section of the embankment. At locations where compactions of the ash fill/earth are impracticable using rollers, such as, fill portions adjacent to masonry structures/steep abutments or around concrete drainpipes embedded in embankment, hand held vibratory tampers shall be used for compaction. The required moisture contents and compaction requirements shall be same as for the rest of the embankment; however, compacted layer thickness should not exceed 100 mm in such cases. The Engineer may permit measurement of field density according to agreed procedure. Subsequent layers shall be placed only after the finished layer has been tested for its density requirements. The contractor shall maintain record of all such tests. When density measurements reveal any soft areas in the embankment, further compaction shall be carried out as directed by the Engineer. In spite of that if specified degree of compaction is not achieved, the material in the soft areas shall be removed and replaced by approved material, moisture content brought to permissible limits and recompacted to the required density. Embankment shall be constructed evenly over their full width and the contractor shall control and direct construction plant and other vehicular traffic uniformly across the width. Damage by the construction plant or other vehicular traffic shall be made good by the contractor with material having the same characteristics and strength as it had before it was damaged. Embankments shall not be constructed with steeper side slopes or to greater width than those shown in the drawings. Whenever embankment construction is to be taken up against the face of natural slope or sloping earth works face including embankments, cuttings, and excavations which are steeper than 1:4 (Vertical:Horizontal), such faces shall be benched immediately before placing the subsequent fill. A less permeable capping layer of selected earth should be constructed on the top of fly ash embankment, which would form the subgrade for the road pavement on top of the embankment. The thickness of this layer should not be less than 500 mm.

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A.3.9 Precautions against Corrosion The sulphate content in fly ash should be within the limits specified in IRC SP 58. The sulphate content of fly ash may sometimes cause concern about possibility of sulphate attack on adjacent concrete structures. Certain precautions are advisable, in case sulphate attack on concrete structures is suspected. These consist of painting the adjacent concrete faces with bitumen or compounds, which offer moisture protection to concrete. Corrosion of cast iron, lead, Copper, PVC or terra cotta pipes would be minimum due to contact with fly ash. If protection of pipes is necessary, polythene sheeting, bituminous coating or embedding and backfilling with inert materials, like, suitable soil of minimum cushion thickness of 500 mm shall be adequate. Where significant volumes of seepage are encountered, pipes should be used to drain the water out of the embankment area. Perforated pipe is usually placed in the vicinity of seep. One-third solid wall pipe with two-third slotted portion can be used to drain the water out of embankment area PVC or ABC pipe materials are preferred because of their long-term performance. Analysis should be performed to confirm that they provide adequate wall strength to support the expected embankn1ent loads. To prevent the internal erosion of the fill, filter protection should be provided around the pipes.

A.3.10 Finishing Operations Finishing operations shall include the work of shaping and dressing the embankment edges and side slopes to conform to the alignment, levels, cross-sections and dimensions shown on the drawing or as directed by the Engineer subject to the tolerance. Both upper and lower ends of side slopes shall be rounded off to improve appearance and to merge the embankment with the adjacent terrain. Incase turfing is proposed, top soil should be provided so that after seeding, a dense cover can develop. The depth of top soil should be sufficient to sustain plant growth, the usual thickness being 75 to 100 mm. Slopes shall be roughened and moistened slightly before the application of top soil in order to provide satisfactory bond. Embankments constructed in flood prone areas should be protected by stone pitching as per the provisions of IRC: 89-1985.

A.4.0 SAMPLING, TESTING AND QUALITY ASSURANCE

Quality of compacted material shall be controlled through periodic checks on fly ash gradation, the compaction process or the end product, singly or in combination as directed. The end product must conform to the specifications.

A.4.1 Control Test on Borrow Material If fly ash from more than one source is being used at the project site, monitoring must be done to identify the ash type being placed. The tests required to be conducted on fly ash to be used as borrow material for embankment are indicated below. The frequency of testing indicated refers to the minimum number of tests to be conducted. The rate of testing must be stepped up as found necessary, depending on the compaction methods employed at the project

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IS Heavy Compaction Test: At the rate of 2 tests per every 3000 m3 of ash, as per IS: 2720 (Part 8)-1983. Moisture Content: One test for every 250m of ash, as per IS: 2720 (Part2)-1973. The Samples collected for testing moisture content should be representative of the material being placed. Because fly ash may air dry relatively rapidly, samples should not be taken from the surface of the lift, but should represent the overall moisture content.

A.4.2 Analysis and Acceptance of Density Results Control shall be exercised on each layer by taking at least one measurement of density for each 1000 square metres of compacted area, or closer as required to yield the minimum number of test results for evaluating a day's work on statistical basis. The determination of density shall be in accordance with IS: 2720 (Part 28)-1974. Test locations shall be chosen by random sampling technique.

A.5.0 RATES AND MEASUREMENTS A.5.1 Rates

The rate for any item in the Schedule, unless specifically excluded in the contract, shall be deemed to include the cost of all materials consumed or used in the work or incidental to it as well as labour, tools, plants, equipment templates, supports, scaffolds, approaches, security and safety measures, power, fuel, lubricants, storage, handling, transport, testing, insurance, taxes, royalties and other revenue expenses, accommodation, services, supervision, overheads, profits etc.

A.5.2 Measurements

A) Earthwork

All earthworks including measurement of fill material from borrow areas, construction of embankment with fly-ash, shall be measured in cu.m. The measurements to be taken shall be those of the authorized dimensions from which soil has been taken out and shall be measured without allowance for increase in bulk.

B) Stripping including storing and reapplication of top soil shall be measured in cu.m.

C) Work involving loosening and re-compacting of ground supporting embankment

shall be measured in cu.m.

D) Removal of unsuitable material at embankment foundation and replacement with suitable material shall be measured in cu.m.

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SECTION 2

TECHNICAL SPECIFICATION FOR LAYING HDPE LINER

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TABLE OF CONTENTS

7.1.0 INTENT 3



7.4.0 TECHNICAL REQUIREMENTS 3



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SECTION 7

TECHNICAL SPECIFICATION FOR

LAYING HDPE LINER 2.1.0 INTENT

This section of the specification covers minimum requirements for the material and furnishing, installation including handling, transporting, protection and repairing till placing pre-cast concrete tiles over the liner and method of measurement.


i. The HDPE geomembrane manufactured from first quality virgin resin only to be used. Blending of resins shall not be allowed. No recycled or reworked geomembrane shall be used except edge trim generated during the manufacturing process (no more than 10%).

ii. The geomembrane shall be free of plasticizers. iii. The geomembrane shall be free of leachable additives. iv. The geomembrane shall be free of factory seams. v. The geomembrane shall be free from dirt, oil, foreign matter, scratches, cracks, creases,

bubbles, blisters, pits, tears, holes, pores, pinholes, voids, un dispersed raw material, any sign of contamination or other defects that may affect serviceability, and shall be uniform in color, thickness and surface texture.

vi. The geomembrane shall be capable of being seamed in the field to yield seams that are as resistant to waste liquids as the sheeting.

2.3.0 CODES AND STANDARDS

i) All applicable standards, acts and codes of practice referred to shall be the latest editions including all applicable official amendments and revisions. The Contractor shall make a complete set of all these documents available at site.

ii) In case of conflict between this specification and those (IS Standards, Codes etc.)

referred to in this clause, the former shall prevail. 2.4.0 TECHNICAL REQUIREMENTS 2.4.1 Materials

HDPE material to be used shall meet the minimum requirements of GRI Standard GM13.

2.4.2 Laying and Installation 2.4.2.1 Panel Layout:

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a. Prior to manufacture and delivery of the geomembrane, a panel layout of the surface to be lined shall be made. Each panel to be used for the installation shall be given a numeric or alphanumeric identification number.

b. The panel identification number shall be related in writing to the manufacturing roll number that identifies the resin type, batch number, and date of manufacturer.

c. The panel layout shall be made considering the following requirements:

i) Panel lengths shall include slope gain and anchorage. ii) Perpendicular tie-ins shall be made a minimum of 5 feet (1.5 m) beyond the toe of the

slope. iii) A minimum of 6 inch (150 mm) overlap shall be allowed at double fusion welded

seams. iv) All field seams on slopes shall be oriented parallel to the slope (oriented along, not

across the slope. v) The number of seams in corners or odd shaped geometric locations shall be

minimized. 2.4.2.2 Packaging

a. The geomembrane shall be delivered to the project site in rolls each wrapped securely with a protective covering installed at the manufacturing facility. The covering shall prevent the entrance of water, vermin and dirt, and shall be adequate for protection against ultraviolet exposure. No material shall be folded.

b. A label shall be attached to each roll of the geomembrane identifying the following:

o Manufacturer. o Product Identification, which can be traced back to the origin of the base material (resin

supplier’s name, resin production plant, resin brand name type, resin brand number, and production date of the resin).

o Date of manufacture of the geomembrane. o Roll identification number. o Geomembrane thickness and type. o Roll dimensions (length and width). o Batch number. o Order number. o Panel number.

c. Packaging and transportation shall be the responsibility of the Manufacturer.

2.4.2.3 Handling of Rolls

The method of off-loading the geomembrane at the project site shall not cause any damage. The rolls shall be placed on a smooth surface free of rocks and standing water.

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2.4.2.4 Storage at the Project Site

Purchaser will provide on-site storage space in a location near where the liner will be placed so that on-site transportation and handling are minimized. The Contractor shall be responsible for protecting the stored material.

2.4.2.5 Cushion Layer below Liner

The liner shall be laid over a 150 mm thick layer of natural sand/ manufactured crusher sand/ bottom ash. The material shall be clean with little or no fines conforming to IS 1498 unless specified otherwise. The Earthwork contractor shall be responsible for preparing and maintaining the surfaces to be lined prior to placement of the liner. The thickness and other arrangement shall be as per the details given in the drawing.

2.4.2.6 Field Placement Of The Liner 2.4.2.6.1 General Requirements:

The placement procedure used for the geomembrane liner shall include the conditions listed below.

i) Weather:

o Geomembrane shall not be placed when the air temperature is above 40oC or below 5oC unless it can be demonstrated to the approval of the Purchaser by trial welds that acceptable welds can be made at the prevailing temperature.

o Geomembrane shall not be placed when there is any rainfall or snowfall, in the presence

of excessive moisture due to fog or dew, in ponded water, on a frozen subgrade, or during high winds.

ii) Panel Layout:

o The panels shall be placed in accordance with the Manufacturer’s panel layout drawing to ensure that they are placed in the proper direction for seaming.

o If panels are installed in a location other than indicated on the panel layout drawing, the

revised location shall be indicated on an "as-built" layout drawing. The “as-built” record drawing shall be submitted to the Purchaser at the completion of the project.

iii) Panel Deployment:

o Only the panels that can be anchored and seamed together in one shift shall be unrolled.

o Unroll and layout panels in as close to the final position as possible. Pulling geomembrane panels should be minimized to reduce the chance of permanent tension.

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o The methods and equipment used to deploy the panels shall not damage the geomembrane or the supporting surface.

o Wrinkles shall be minimized. However, enough slack shall be provided in both directions so that there will be no tension in the geomembrane at the lowest expected operating temperature.

iv) Precautions to Prevent Wind Damage:

o If possible, work shall be oriented in the direction of the prevailing wind.

o Provide adequate temporary loading and/or anchoring of the geomembrane by the use of sandbags, tires or other means which will not damage the geomembrane, to prevent uplift of the geomembrane by wind.

v) Other Precautions to Prevent Damage:

o Protection of the geomembrane from damage due to foot traffic on the slopes shall be provided.

o Provisions of facilities for safe entrance and egress of employees from sloped depressions is required.

vi) Replacement of Damaged Geomembrane:

Any area of a panel, which, in the judgment of the Purchaser, becomes seriously damaged (torn, twisted, or crimped permanently), shall be replaced at no additional cost to the Purchaser.

2.4.2.6.2 Field Seaming: i) Method of Seaming:

o The primary welding procedure for seams shall be double wedge fusion welding.

o Extrusion welding shall be used only for repairs, detail work, and for seaming where double wedge fusion welding is not possible.

o The rods used for extrusion welding shall be the same type of resin as the geomembrane, unless otherwise approved by the Purchaser.

o The use of solvents or adhesives is not permitted.

ii) General Requirements for Seaming:

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o On slopes steeper than 10 horizontal to 1 vertical, seams shall be oriented parallel to the line of maximum slope (oriented up and down, not across the slope) when possible. No seams oriented across the slope shall be used unless approved by the Purchaser.

o Seams parallel to the toe of the slope shall be located a minimum of 5 feet (1.5 m) from the toe.

o Seams parallel to the crest of the slope shall be located a minimum of 2 feet (600 mm) from the crest.

o Seams on the floor of the pond shall be overlapped so that the upslope sheet is positioned above the down slope sheet.

o Seaming shall extend to the outside edge of panels to be placed in the anchor trench. Seams at corners of three or four sheets shall be completed with a patch having a minimum dimension of 24 inches (600 mm), and extrusion welded to the parent sheets.

o All cross seams between the two rows of seamed panels shall be welded during the coolest time of the day to allow for contraction of geomembrane.

iii) Trial Welds Prior to Beginning Seaming:

Trial welds are required for pre-qualification of personnel, equipment and procedures for making seams on identical geomembrane material under the same climatic conditions as the actual field production seams will be made. Trial welds shall be made as follows:

o Prior to each seaming period.

o Every 4 to 5 hours (i.e., at the beginning of the work shift and after the lunch break).

o Whenever personnel or equipment are changed.

o When climatic conditions result in wide changes in geomembrane temperature.

o When requested by QC & QA (Quality Control & Quality Assurance) Geomembrane

Inspector for any seaming crew or piece of welding equipment if problems are suspected.

Once qualified by passing a trial weld, welding technicians shall not change parameters without performing another trial weld. Trial welds shall be made on both double wedge fusion welds and on extrusion welds. A test strip shall be prepared by joining two pieces of geomembrane; each piece shall be at least 6 inches (150 mm) wide. The length of double wedge fusion welded seams shall be a minimum of 10 feet (3 m) long. The length of an extrusion welded seam shall be a minimum of 4 feet (1.2 m) long. The CQA Geomembrane Inspector shall witness the fabrication of each test strip. All test welds shall be tested by destructive testing. Testing can be done as soon as the seam cools. If any of the test specimens fail, a new test strip shall be fabricated and the tests repeated

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for the new strip. If additional specimens fail, the seaming apparatus and the seamer shall not be accepted and shall not be used for seaming until the deficiencies are corrected and successful trial welds have been achieved. If the specimens pass the tests, production seaming operations can begin.

iv) Preparation for Seaming:

o Prior to seaming, the surface of the geomembrane shall be wiped with a clean cloth to ensure that it is clean and free from moisture, grease, dust, dirt, and debris of any kind before seam welding is started.

o The panels shall be adjusted so that the seams are aligned to eliminate wrinkles and fish

mouths. Where necessary, fish mouths and wrinkles shall be cut to achieve flat overlap. v) Seaming:

o Seaming shall be performed in accordance with the Manufacturer's accepted procedure.

o Double Wedge Fusion Welds: The panels shall be overlapped a minimum of 4 inches (100 mm) prior to welding. Vehicle mounted automated hot wedge welding apparatus shall be used to make the seam.

o Extrusion Fillet Welding: Geomembrane overlap shall be a minimum of 3 inches (75 mm) for extrusion welding. Panels shall be temporarily bonded using a hot air device prior to extrusion welding. The edge of the geomembrane to be fillet welded shall be pre-beveled before heat-tacking the seam in place. The seam overlap shall be ground (abraded) no more than one hour prior to welding. Grinding shall be performed in accordance with the Manufacturer’s instructions in a manner that does not damage the geomembrane. Grinding shall not extend more than 1/4 inch past the area to be covered with extrudate during welding. All grind marks shall be covered with extrudate.

2.4.2.6.3 Non-Destructive Field Testing – Geomembrane:

i) General: o All non-destructive field testing shall be performed and documented by the

Geomembrane Contractor. o The QC & QA Geomembrane Inspector shall observe all non-destructive test

procedures.

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o One hundred (100) percent of the seam length shall be tested using non-destructive procedures to check the continuity of the field seams. Non-destructive testing is not meant to qualify seam strength.

o Air pressure testing shall be performed in accordance with ASTM D5820 and GRI GM

6. o Vacuum Box testing shall be performed in accordance with ASTM D5641 and as

specified herein. o Continuity testing shall be performed as seaming progresses or as soon as a suitable

length of seam is available, not at the completion of all field seaming.

ii) Double Wedge Fusion Welded Seams: o Double fusion welded seams shall be tested using air pressure testing. o The procedure for testing shall be as specified in GRI GM 6 for the type and thickness of

geomembrane in use. o The leak or suspected leak shall be located and repaired. o The repaired seam shall be re-tested as required until all leaks are identified, and

repaired, and the seam passes a subsequent air pressure test. o When the geometry of a double wedge fusion weld makes air testing impossible or

impractical, vacuum testing may be used to test the seam. iii) Extrusion Welded Seams: o Extrusion welded seams shall be tested using vacuum chamber testing in accordance

with ASTM D5641. o The completed seam shall exhibit no leakage when tested between 4 and 8 psi minimum

vacuum for approximately 10 seconds. o If leaks are discovered during testing, they shall be located, marked, and repaired. o The repaired area shall be re-tested and exhibit no leakage.

2.4.2.6.3 Destructive Testing – Geomembrane: i) Testing: o Destructive testing shall be performed by an independent third party laboratory

employed by the Geomembrane Contractor on samples cut from production welds in the field by the Geomembrane Contractor.

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o Samples shall be taken by the Geomembrane Contractor to the third party laboratory and

tested for shear strength and peel adhesion. For double wedge seam samples, both welds shall be tested for peel adhesion.

o The third party laboratory that will perform testing shall be identified by the

Geomembrane Contractor with the bid proposal and agreed-to in writing by the Purchaser.

2.4.2.6.4 Repair Of Defects And Seams - Geomembrane

i) Patching:

o Patching shall be used to repair large holes, tears and destructive sample locations.

o All patches shall be round, oval, or shall have rounded corners.

o All patches shall be made of the base geomembrane material and shall extend a minimum of 3 inches beyond the edges of the defect.

o Patches shall be extrusion welded to the base sheet.

ii) Grinding and Welding:

Grinding and welding shall be used to repair sections of extruded fillet seams with small defects.

iii) Spot Welding:

Spot welding shall be used to repair small tears, pinholes, or other minor localized flaws. 2.4.2.6.5 Crest Anchor Trench Excavation And Backfilling

The geomembrane liner shall be anchored in anchor trench at the top and bottom of the slope and at berm locations as shown on the Design Drawings. The excavation for anchor trench shall be done by the contractor to the lines and widths shown on the drawings prior to placement of the liner. Excavated anchor trench shall be filled with flyash bricks or crushed aggregates carefully so that sufficient anchorage is ensured while laying the HDPE membrane.


iii) The Contractor shall carry out all sampling and testing in accordance with the relevant Indian Standards and/or International Standards and shall conduct such tests as are called for by the Purchaser / Engineer. Where no specific testing procedure is

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mentioned, the tests shall be carried out as per the prevalent accepted engineering practice to the directions of the Purchaser / Engineer. Tests shall be done in the field and at a laboratory approved by the Purchaser / Engineer and the Contractor shall submit the test results in triplicate within three days after completion of a test to the Purchaser / Engineer. The Purchaser / Engineer may, at his discretion, waive off some of the stipulations given below, for small and unimportant operations.

iv) Material / work found unsuitable for acceptance shall be removed and replaced by

the Contractor. The works shall be redone as per specification requirements and to the satisfaction of the Purchaser / Engineer.


The Contractor shall submit and finalize a detailed field Quality Assurance Program within 30 days from the date of award of the Contract according to the requirements of the specification. This shall include settling up of a testing laboratory, arrangement of testing apparatus / equipment, deployment of qualified / experienced manpower, preparation of format for record, field quality plan etc. On finalized field quality plan, the Purchaser / Engineer shall identify, customer hold points beyond which work shall not proceed without written approval from the Purchaser / Engineer.


v) The items of work in Schedule of Items describe the work in brief. The various items of the Schedule of Items shall be read in conjunction with the corresponding sections in the technical specifications including amendments and additions, if any. For each item in the Schedule of Items, the Contractor's quoted rate shall include the activities covered in the description of the item as well as all necessary operations described in the specifications.

vi) Contractor's quoted rate for each item shall include minor details which are

obviously and fairly intended and which may not have been included in descriptions in these documents but are essential for the satisfactory completion of the work. Quoted rate for each item shall also include for taking all safety measures as required by provisions of applicable codes, local regulations / acts etc. and for execution to the satisfaction of the Purchaser / Engineer.

vii) Contractor's quoted rate for each item shall be inclusive of providing all plant,

equipment, men, materials including supply of cement, skilled and unskilled labour, making observations, supervision and establishing the ground level and coordinates at location of each work by carrying levels from one set of grid lines furnished by the Purchaser / Engineer etc.

viii) Contractor's quoted rate for each item shall also include for all sampling, testing,

quality assurance requirements, inspection etc. The rates shall be all inclusive of providing temporary works, wastage, addition of extra cement if required,

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overheads, profits and all such requirement. No extra shall be payable over and above the quoted rate.

ix) No claim shall be entertained if the details, shown on the ‘released for

construction’ drawings differ in any way from these shown on the drawings enclosed with the tender documents, unless the nature of work is different.

x) Contractor's quoted rates for lining shall include the following :

Supplying, storage and installation of liner. Repairing all defects and providing precautionary measures to protect the rolls.

Welding of sheets

Testing of seams.

xi) Contractors quoted rates for preparation of surface to be lined shall include the

following;

Supplying and laying cushion material (sand/ manufactured sand/ bottom ash) for surface preparation.

Leveling and trimming the surface of cushion layer.

xii) Contractors quoted rates for concrete tiles shall include the following;

Casting and installation of tiles including pointing. Preparation of mortar bed.

Supplying and placing of wire mesh.

xiii) Contractor’s quoted rate for demolition shall include the following:

Separating out and stacking properly the serviceable materials up to a lead of 500 m or handing over to Purchaser / Engineer's stores and disposing off unserviceable materials up to a lead of 2 km.

Necessary propping, shoring and underpinning for the safety of a portions not required to be pulled down or of adjoining property and providing temporary supports and enclosures or partitions where specified, including safety of men and materials.

Providing, dismantling and removing the scaffolding.

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2.6.2 Measurements

xiv) HDPE liner on embankment slope and over bed of ash pond shall each be measured separately in square meters stating the liner thickness.

xv) For cushion layer below liner, measurements shall be in cubic meter based on the

profile as per construction drawings or the actual profile whichever is less.

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SECTION 3

TECHNICAL SPECIFICATION FOR NON-WOVEN GEOTEXTILE

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TABLE OF CONTENTS

3.1.0 INTENT 3






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SECTION 3


GEOTEXTILE MEMBRANE 3.1.0 INTENT

This section of the specification covers minimum requirements for the material and furnishing, installation including handling, transporting, protection and repairing till placing non-woven geotextile laid and its method of measurement.


i. The non-wown geotextile shall be manufactured from first quality virgin resin. Blending of resins shall not be allowed. No recycled or reworked geotextile shall be used except edge trim generated during the manufacturing process (no more than 10%).

ii. The geotextile shall be free of plasticizers. iii. The geotextile shall be free of leachable additives. iv. The geotextile shall be free of factory seams. v. The g geotextile shall be free from dirt, oil, foreign matter, scratches, cracks, creases,

bubbles, blisters, pits, tears, holes, pores, pinholes, voids, un dispersed raw material, any sign of contamination or other defects that may affect serviceability, and shall be uniform in color, thickness and surface texture.

vi. The geotextile shall be capable of being seamed in the field to yield seams that are as resistant to waste liquids as the sheeting.



ii) In case of conflict between this specification and those (IS Standards or British

standards) referred to in this clause, the former shall prevail. 3.4.0 TECHNICAL REQUIREMENTS 3.4.1 Materials

The nonwoven thermally bonded or needle punched or any equivalent geotextile shall be used. The geotextile shall be made of polyethylene or Polypropylene or polyester or similar fibers manufactured through machine made process of heat bonding or needle punching techniques. The mean Values of Geo-textile shall be as shown in Table1.

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Table 1. Guide property of non woven geotextile Properties Mean Values Test Method MechanicalWide width Strip Tensile 5 kN/m EN ISO 10319 Elongation 30-50 % EN ISO 10319 CBR Puncture resistance 2500 EN ISO 12236 Hydraulic Apparent opening size 85 microne EN ISO 12956 Permeability 45 l/m2. sec EN ISO 11058 Physical Mass per unit area 150-300 g/sq.m. Thickness 1 to 2 mm Note: Above properties are indicative and for guidance purpose only. Bidder shall submit the data sheet of the product they intend to use.

3.4.2 Laying and Installation 3.4.2.1 Panel Layout:

a. Prior to manufacture and delivery of the geotextile, a panel layout of the surface to be lined shall be made. Each panel to be used for the installation shall be given a numeric or alphanumeric identification number.

b. The panel identification number shall be related in writing to the manufacturing roll number that identifies the resin type, batch number, and date of manufacturer.

c. The panel layout shall be made considering the following requirements:

i) Panel lengths shall include slope gain and anchorage. ii) Perpendicular tie-ins shall be made a minimum of 5 feet (1.5 m) beyond the toe of the

slope. iii) A minimum of 6 inch (150 mm) overlap shall be allowed at double fusion welded

seams. iv) All field seams on slopes shall be oriented parallel to the slope (oriented along, not

across the slope. v) The number of seams in corners or odd shaped geometric locations shall be

minimized. 2.4.2.2 Packaging

a. The geotextile shall be delivered to the project site in rolls each wrapped securely with a protective covering installed at the manufacturing facility. The covering shall prevent the entrance of water, vermin and dirt, and shall be adequate for protection against ultraviolet exposure. No material shall be folded.

b. A label shall be attached to each roll of the geotextile identifying the following:

o Manufacturer.

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o Product Identification, which can be traced back to the origin of the base material (resin supplier’s name, resin production plant, resin brand name type, resin brand number, and production date of the resin).

o Date of manufacture of the geotextile. o Roll identification number. o Geotextile thickness and type. o Roll dimensions (length and width). o Batch number. o Order number. o Panel number.

c. Packaging and transportation shall be the responsibility of the Manufacturer.

3.4.2.3 Handling of Rolls

The method of off-loading the geotextile at the project site shall not cause any damage. The rolls shall be placed on a smooth surface free of rocks and standing water.

3.4.2.4 Storage at the Project Site

Purchaser will provide on-site storage space in a location near where the liner will be placed so that on-site transportation and handling are minimized. The Contractor shall be responsible for protecting the stored material.

3.4.2.5 Cushion Layer below Geotextile

The Geotextile shall be laid over a 150 mm thick layer of natural sand/ manufactured crusher sand/ bottom ash. The material shall be clean with little or no fines conforming to IS 1498 unless specified otherwise. The Earthwork contractor shall be responsible for preparing and maintaining the surfaces to be lined prior to placement of the liner. The thickness and other arrangement shall be as per the details given in the drawing.

3.4.2.6 Field Placement Of The Liner 3.4.2.6.1 General Requirements:

The placement procedure used for the geotextile liner shall include the conditions listed below.

i) Weather:

o Geotextile shall not be placed when the air temperature is above 40oC or below 5oC unless it can be demonstrated to the approval of the Purchaser by trial welds that acceptable welds can be made at the prevailing temperature.

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o Geotextile shall not be placed when there is any rainfall or snowfall, in the presence of excessive moisture due to fog or dew, in ponded water, on a frozen subgrade, or during high winds.

ii) Panel Layout:

o The panels shall be placed in accordance with the Manufacturer’s panel layout drawing to ensure that they are placed in the proper direction for seaming.

o If panels are installed in a location other than indicated on the panel layout drawing, the

revised location shall be indicated on an "as-built" layout drawing. The “as-built” record drawing shall be submitted to the Purchaser at the completion of the project.

iii) Panel Deployment:

o Only the panels that can be anchored and seamed together in one shift shall be unrolled.

o Unroll and layout panels in as close to the final position as possible. Pulling geotextile panels should be minimized to reduce the chance of permanent tension.

o The methods and equipment used to deploy the panels shall not damage the geotextile or the supporting surface.

o Wrinkles shall be minimized. However, enough slack shall be provided in both directions so that there will be no tension in the geotextile at the lowest expected operating temperature.

iv) Precautions to Prevent Wind Damage:

o If possible, work shall be oriented in the direction of the prevailing wind.

o Provide adequate temporary loading and/or anchoring of the geotextile by the use of sandbags, tires or other means which will not damage the geotextile, to prevent uplift of the geotextile by wind.

v) Other Precautions to Prevent Damage:

o Protection of the geotextile from damage due to foot traffic on the slopes shall be provided.

o Provisions of facilities for safe entrance and egress of employees from sloped depressions is required.

vi) Replacement of Damaged Geotextile:

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Any area of a panel, which, in the judgment of the Purchaser, becomes seriously damaged (torn, twisted, or crimped permanently), shall be replaced at no additional cost to the Purchaser.

3.4.2.6.5 Crest Anchor Trench Excavation and Backfilling

The geotextile liner shall be anchored in anchor trench at the top and bottom of the slope and at berm locations as shown on the Design Drawings. The excavation for anchor trench shall be done by the contractor to the lines and widths shown on the drawings prior to placement of the liner. Excavated anchor trench shall be filled with flyash bricks or crushed aggregates carefully so that sufficient anchorage is ensured while laying the HDPE membrane.


iii) The Contractor shall carry out all sampling and testing in accordance with the relevant Indian Standards and/or International Standards and shall conduct such tests as are called for by the Purchaser / Engineer. Where no specific testing procedure is mentioned, the tests shall be carried out as per the prevalent accepted engineering practice to the directions of the Purchaser / Engineer. Tests shall be done in the field and at a laboratory approved by the Purchaser / Engineer and the Contractor shall submit the test results in triplicate within three days after completion of a test to the Purchaser / Engineer. The Purchaser / Engineer may, at his discretion, waive off some of the stipulations given below, for small and unimportant operations.

iv) Material / work found unsuitable for acceptance shall be removed and replaced by

the Contractor. The works shall be redone as per specification requirements and to the satisfaction of the Purchaser / Engineer.


The Contractor shall submit and finalize a detailed field Quality Assurance Program within 30 days from the date of award of the Contract according to the requirements of the specification. This shall include settling up of a testing laboratory, arrangement of testing apparatus / equipment, deployment of qualified / experienced manpower, preparation of format for record, field quality plan etc. On finalized field quality plan, the Purchaser / Engineer shall identify, customer hold points beyond which work shall not proceed without written approval from the Purchaser / Engineer.


v) The items of work in Schedule of Items describe the work in brief. The various items of the Schedule of Items shall be read in conjunction with the corresponding sections in the technical specifications including amendments and additions, if any.

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For each item in the Schedule of Items, the Contractor's quoted rate shall include the activities covered in the description of the item as well as all necessary operations described in the specifications.

vi) Contractor's quoted rate for each item shall include minor details which are

obviously and fairly intended and which may not have been included in descriptions in these documents but are essential for the satisfactory completion of the work. Quoted rate for each item shall also include for taking all safety measures as required by provisions of applicable codes, local regulations / acts etc. and for execution to the satisfaction of the Purchaser / Engineer.

vii) Contractor's quoted rate for each item shall be inclusive of providing all plant,

equipment, men, materials including supply of cement, skilled and unskilled labour, making observations, supervision and establishing the ground level and coordinates at location of each work by carrying levels from one set of grid lines furnished by the Purchaser / Engineer etc.

viii) Contractor's quoted rate for each item shall also include for all sampling, testing,

quality assurance requirements, inspection etc. The rates shall be all inclusive of providing temporary works, wastage, addition of extra cement if required, overheads, profits and all such requirement. No extra shall be payable over and above the quoted rate.

ix) No claim shall be entertained if the details, shown on the ‘released for

construction’ drawings differ in any way from these shown on the drawings enclosed with the tender documents, unless the nature of work is different.

x) Contractor's quoted rates for lining the reservoir shall include the following :

Supplying, storage and installation of liner. Repairing all defects and providing precautionary measures to protect the rolls.

Testing of seams.

xi) Contractors quoted rates for preparation of surface to be lined shall include the

following;

Supplying and laying sand for surface preparation. Leveling and trimming the surface of sand layer.

xii) Contractors quoted rates for concrete tiles shall include the following;

Casting and installation of tiles including pointing. Preparation of mortar bed.

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Supplying and placing of wire mesh.

xiii) Contractor’s quoted rate for demolition shall include the following:

Separating out and stacking properly the serviceable materials up to a lead of 500 m or handing over to Purchaser / Engineer's stores and disposing off unserviceable materials up to a lead of 2 km.

Necessary propping, shoring and underpinning for the safety of a portions not required to be pulled down or of adjoining property and providing temporary supports and enclosures or partitions where specified, including safety of men and materials.

Providing, dismantling and removing the scaffolding. 3.6.2 Measurements

xiv) Geotextile membrane on embankment slope (for rock toe) shall be measured separately in square meters stating the thickness of geotextile.

xv) For cushion layer below Geotextile, measurements shall be in cubic meter based on

the profile as per construction drawings or the actual profile whichever is less.

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SECTION 4

TECHNICAL SPECIFICATION FOR DRAINAGE FILTER AND ROCK TOE

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CONTENTS

4.1.0 INTENT 3






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SECTION 4


DRAINAGE FILTER AND ROCK TOE 4.1.0 INTENT

This section of the specification covers supplying and forming of horizontal drainage filter on the foundation of the embankment, vertical / inclined sand chimney in the embankment below rock toe and along the slope and rock toe as indicated in the drawings.


i) This part of the specification covers the requirement for material and placing of filters and rock toe for ash pond divide bund. Filters and the toe shall be laid true to line and level as shown on drawings. All materials shall be compacted to required density as described in this specification or as shown in the drawings.

ii) The Contractor shall furnish all skilled and unskilled labour, plant, equipment,

scaffolding, materials etc. required for complete execution of the work in accordance with the drawings and as described herein and / or as directed by the Purchaser/ Engineer.

iii) All workmanship shall be in accordance with the latest standards and best possible

practices.

iv) The Contractor shall carry out all works for establishing the levels on the basis of reference lines and bench mark, which shall be furnished by the Purchaser / Engineer, at one or more locations.

v) Any approval, instructions, permission, checking, review, etc. whatsoever by the

Purchaser / Engineer shall not relieve the Contractor of his responsibility and obligation regarding adequacy, correctness, completeness, safety, strength, quality, workmanship, etc.



ii) In case of conflict between this specification and those (IS Standards, Codes etc.)

referred to in this clause, the former shall prevail.

iii) Some of the applicable Indian Standards, Codes, etc. are referred here below :

IS: 383 Specification for coarse and fine aggregates from natural sources.

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IS: 9429 Code of Practice for Drainage System for Earth and Rockfill Dams IS: 2720 Methods of Test for Soils (Relevant Parts) IS: 8826 Guidelines for design of large earth and rockfill dams IS: 1498 Classification and identification of soils for general engineering

purposes 4.4.0 TECHNICAL REQUIREMENTS

As indicated in the drawing graded sand blanket, sand chimney or graded sand filter and the rock toe shall be laid in the embankment. The thickness of the filter layers shall be as specified or as directed by the Engineer.

4.4.1 Materials

For Drainage Filter: The material for blanket, chimney and sand filters shall consist of clean, sound and well graded coarse sand. The materials shall be free from debris wood, vegetable matter and other deleterious matter. The gradation of sand material shall meet the requirements as specified below:

a)

D50 of filter

D50 of base material25

b)

D15 of filter

D 15 of base material 6 to 19

c)

D 85 of filter

D 15 of filter 5

d)

D15 of filter

D 85 of base material 5

e) The gradation curve of the filter material shall be nearly parallel to the

gradation curve of the base material. f) The filters shall not contain more than 5% by weight of materials finer than

0.075 mm size. g) The sand filter layer shall be considered as the base material for coarser filter

layer. h) The filter material shall be suitably compacted to a firm condition to achieve

a relative density of 70 %.

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i) In addition to the above, the provisions for filter as given in "IS: 9429-Code of practice for drainage system for Earth and Rock Fill dam", also shall be followed.

For sand- material, the grading shall be decided as per filter criteria specified above, such that the embankment fill material is prevented from being carried away through the blanket, chimney and filters. For Rock Toe: The rock material used for the rock toe shall satisfy the following condition: a) Specific gravity shall not be less than 2.50 (As per IS 1122)

b) Sulphate soundness- Less than 10% loss of weight after (Five) cycles (As per IS I 120)

c) Aggregate Impact value shall not exceed 16% (As per IS 2380) d) Water absorption shall not exceed 2.5% (As per IS 2386)

e) In slake durability test (as per IS 10050), the percentage retain after two ten (10) minutes cycles shall be more than 85 %.

Rock toe shall be formed with rock material consisting of sound, durable and well graded broken rock obtained from approved quarries and shall be of approved quality prior to being transported to the area of deposition. The materials shall range in size from 10 to 45 cm. All brush, roots or other perishable materials shall be removed from rock-fill during spreading and shall be transported to a disposal area. The rock available from the excavation of water escape structure/stripping/drain channel etc. which satisfy the quality requirements specified above and found suitable for construction of rock toe by Engineer shall be used. These shall be washed, cleared, and broken into required size and stacked separately, at a place as directed by the Engineer. Similarly, rock materials for rock toe satisfying the quality requirements specified above can also be obtained from rock available within the land acquired for construction of ash pond divide bund, if it is found suitable. The rock will be broken to required size and shape and will be cleaned before utilized.

4.4.2 Placing

a. Sand Blanket

Sand blanket shall be laid subsequent to site clearance, stripping and excavation, if any. The foundation area shall be cleared before laying the bottom layer of blanket material. Filter material shall be laid in layers not exceeding 150 mm. Water as found necessary shall be sprinkled before compaction. Care shall be taken to ensure that materials of different layers do not get mixed, both at the time of placing and during compaction. Extreme care shall be taken when placing materials in the zone to obtain a fill free from lenses, layers and streaks of segregated materials. After the layers of filter blanket

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material and intermediate sand layer materials have been laid and compacted as directed by the Engineer earth fill material shall be laid.

b. Sand Chimney

Sand chimney of specified thickness shall be laid at the specified location by excavating and removing the already compacted embankment material exposing sand chimney in the lower layers earlier laid, and refilling the trench with sand with in layers. The layer of sand shall be well watered and rammed. The depth of each layer of chimney to be laid shall not be more than 150 mm or as directed by the Engineer. The excavated material can be reused in the embankment area. While excavating the earth for filling sand for chimney drain, the top layer of sand which has been mixed with earth, shall also be removed. Alternatively, the sand chimney can also be laid in layers simultaneously with the laying of each layer of earth fill. In such case, the top level of sand layer shall always be kept at about 100 cm above earth level on both sides. Each layer of sand shall be well watered and rammed. Care shall be taken to avoid mixing of earth and sand.

c. Sand Filter

The sand filter underneath the rock-toe and between rip rap and the bund shall closely follow the levels of the embankment in the area. Sand filter shall be laid subsequent to stripping of foundation and/or trimming of slope of compacted bund. The excavated earth shall be removed from the working area and stockpiled at a place directed by the Engineer. The surface to receive the sand filter shall be properly cleaned before laying of filter material. The sand filter shall be laid in layers; the thickness of the layers shall not be more than 150 mm or as directed by the Engineer. Water as found necessary shall be sprinkled before compaction. The sand layer shall be well watered and rammed. Care shall be taken that materials of different layers do not get mixed, both at the time of placing and during compaction. The sand filter material shall be clean, sound, durable and well graded. No debris, wood, deleterious material etc., shall be permitted. d. Rock Toe

The stone pieces shall be hand placed to obtain a stable, well graded and free draining fill. The rock toe shall be constructed in layers so that the smaller rock fragments shall be placed adjacent to the filter of embankment and the large rock fragments near the outer edge of the rock toe. The rock fill shall be hand placed, spread and roughly leveled in layers not greater than 300 mm in thickness in order to maintain a reasonably uniform surface and ensure that the completed fill will be stable and not contain any voids having least dimension larger than 50 mm. Contamination of the rock with finer materials from any other zones shall be avoided. Accumulations of soil caused by contamination shall be removed.

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Rock materials shall not be dumped directly against any concrete or masonry structure, but shall be hand placed in layers.


iv) Material / work found unsuitable for acceptance shall be removed and replaced by the Contractor. The works shall be redone as per specification requirements and to the satisfaction of the Purchaser / Engineer.

v) Material, placing procedures and installations and test conducted by the Contractor

are subject to inspection. Such inspections and tests shall not relieve Contractor of responsibility for providing material and placement in compliance with this specification.


The Contractor shall submit and finalize a detailed Field Quality Assurance (FQA) Program, within 30 days, from the date of award of the Contract according to the requirements of the specification. This shall include setting up of a testing laboratory, arrangement of testing apparatus/equipment, deployment of qualified/ experienced manpower, preparation of format for record, Field Quality Plan, etc. On finalizing field quality plan, the Contractor shall identify hold points beyond which work shall not proceed without written approval from the Engineer.


vi) The item of work in the Schedule of Quantities describes the work in brief. The various items of the Schedule of Quantities shall be read in conjunction with the corresponding sections in the technical specifications including amendments and additions, if any. For each item in the Schedule of Quantities, the Contractor’s rates shall include the activities covered in the description of the item as well as all necessary operations described in the specifications.

vii) The Contractor’s quoted rates shall include all minor details which are obviously

and fairly intended and which may not have been included in the description in these documents but are essential for the satisfactory completion of the work. Quoted rates shall also include for taking all safety measures as required by Codal provisions, local regulations etc. and for execution to the satisfaction of the Engineer. Clearing all grass, vegetation etc. shall be inclusive in the rate.

viii) The Contractor’s quoted rate for each item shall be inclusive of providing all plant,

equipment, men, materials, skilled and unskilled labour, making observations, surveying/ establishing the ground level and co-ordinates at location of each work

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by carrying levels from one established bench mark and distances from one set of grid lines furnished by the Engineer/Purchaser.

ix) Rates shall also include for all testing, quality control requirements, arranging

inspection, etc. The rates quoted shall be all inclusive of providing temporary works, wastage, overheads, profits and all such requirement. Nothing extra shall be payable over and above the quoted rates on these accounts. Rates shall include for any additional excavation and filling for all leads and lifts, including transportation to disposal area and bringing back for refilling with proper compaction as specified, if any, beyond the payment line.

x) No claims whatsoever shall be entertained if the detail shown on the ‘Released for

construction drawings’ differ in any way from those shown on the bid/tender drawings.

4.6.2 Measurements

All measurements shall be in SI units.

xi) Linear measurement shall be in meters (m) correct upto second place of decimal. Areas and volumes shall be calculated from the linear measurements and shall be in square meters and cubic meters respectively, rounded off to two decimal places. For rounding off, values in the third decimal place which are below 5 shall be ignored and those 5 and above shall be taken as 10.

xii) For each item of work, the total quantity for payment at quoted rate shall be the

lesser of actual quantity executed and that evaluated on the basis of the method of measurements given herein.

xiii) All measurements shall be recorded by the Contractor and duly certified/ approved

by the Engineer. Measurement for all filters and rock toe shall be made in cubic meter (m3). The quantity shall be calculated from the drawing and as executed quantity shall be obtained by applying the as executed thickness to the levels and cross-section of earthen embankment. Lesser of the two quantities shall be considered for payment. Payment shall be made at the rate of relevant item of schedule for the quantity arrived above. Measurement shall be done separately for the rock toe with materials obtained from the following sources. a) Rock obtained from excavation and stripping work. b) Rock obtained from within the acquired land. c) Rock to be supplied from quarries.

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SECTION 5


CAST-IN-SITU CONCRETE AND ALLIED WORKS

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CONTENTS

CAST-IN-SITU CONCRETE AND ALLIED WORKS 3

5.0.1 INTENT 3 5.0.2 GENERAL REQUIREMENTS 3 5.0.3 CODES AND STANDARDS 4 5.0.4 TECHNICAL REQUIREMENTS – INSTALLATION 9 5.0.5 SAMPLING, TESTING AND QUALITY ASSURANCE 9 5.0.6 RATES AND MEASUREMENTS 14

SUB SECTION - I 15

CAST-IN-SITU CONCRETE 16

5.1.1 INTENT 16 5.1.2 GENERAL REQUIREMENTS 16 5.1.3 CODES AND STANDARDS 22 5.1.4 TECHNICAL REQUIREMENTS - INSTALLATION 23 5.1.5 SAMPLING, TESTING AND QUALITY ASSURANCE 31 5.1.6 RATES AND MEASUREMENTS 35

SUB SECTION - II 37

REINFORCEMENT 37

5.2.1 INTENT 37 5.2.2 GENERAL REQUIREMENTS 37 5.2.3 CODES AND STANDARD 37 5.2.4 TECHNICAL REQUIREMENTS - INSTALLATION 37 5.2.5 SAMPLING, TESTING AND QUALITY ASSURANCE 40 5.2.6 RATES AND MEASUREMENTS 40

SUB SECTION - III 42

FORMWORK AND STAGING 42

5.3.1 INTENT 42 5.3.2 GENERAL REQUIREMENTS 42 5.3.3 CODES AND STANDARDS 43 5.3.4 TECHNICAL REQUIREMENTS – INSTALLATION & REMOVAL 43 5.3.5 SAMPLING, TESTING AND QUALITY ASSURANCE 47 5.3.6 RATES AND MEASUREMENTS 48

SUB SECTION - IV 49

EMBEDDED PARTS 49

5.4.1 INTENT 49 5.4.2 GENERAL REQUIREMENTS 49 5.4.3 CODES AND STANDARDS 49 5.4.4 TECHNICAL REQUIREMENTS - INSTALLATION 50 5.4.5 SAMPLING, TESTING AND QUALITY ASSURANCE 51 5.4.6 RATES AND MEASUREMENTS 51

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SECTION 5

TECHNICAL SPECIFICATION FOR CAST-IN-SITU CONCRETE AND ALLIED WORKS

5.0.1 INTENT

i) The work shall include providing of materials, all necessary plants and equipment, providing adequate engineering supervision and technical personnel, skilled and unskilled labour, etc. as required to carry out the entire work as indicated on the drawings and/or described herein subsequently and/or as directed by the Engineer / Purchaser.

ii) The Contractor shall carry out all works meant within the intent of this

specification even if not explicitly mentioned herein. All works shall be executed to the satisfaction of the Engineer / Purchaser.

iii) This specification of specification is divided into 13 Sub-Sections. This section

deals with common requirements and the other 13 Sub-Sections deal with specifications for 13 different items/activities. The stipulations contained herein shall form a part of the specifications of 13 different items/activities described in Sub-Sections I to XIII

All these thirteen Sub-Sections are as follows:

SUB SECTION - I Cast-in-Situ Concrete SUB SECTION - II Reinforcement SUB SECTION - III Formwork and staging SUB SECTION - IV Embedded parts SUB SECTION - V Foundation bolt assembly SUB SECTION - VI Shotcreting SUB SECTION - VII Grouting SUB SECTION - VIII Encasement of steel structures/elements SUB SECTION - IX Joints in Concrete SUB SECTION - X Water proofing/damp proofing of Concrete structures. SUB SECTION - XI Dismantling/Demolishing works-RCC and PCC. SUB SECTION - XII Cement Additives/Admixtures in concrete. SUB SECTION - XIII Concreting of major equipment foundations.

iv) Precast and pre-stressed concrete work specification, have been dealt separately.

Special requirements for machine foundations like BFP, TG, fan, mill and crusher foundation, chimney, natural draught cooling tower, piling, etc. have been covered in this specification separately in Sub-Section XIII and also applicable clauses of this specification / other sections shall be followed for the construction of the Machine foundation.


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i) Any approval, instructions, permission, checking, review, etc. whatsoever by the Engineer / Purchaser, shall not relieve the Contractor of his responsibility and obligation regarding adequacy, correctness, completeness, safety, strength, quality, workmanship, etc.

ii) The Contractor shall make his own surveying arrangements for locating the co-

ordinates and positions of all work and establishing the reduced levels (RLs) at these locations, based on two reference grid lines and one bench mark, which will be furnished by the Purchaser. The Contractor has to provide at site, all the required survey instruments, along with qualified surveyors, to the satisfaction of the Engineer / Purchaser so that the work can be carried out accurately and according to the specifications and drawings.


i) All applicable standards, specifications, etc. and codes of practice shall generally be the latest editions, including all applicable official amendments and revisions. A complete set of all these documents shall generally be made available at site by the Contractor.

ii) All work shall be carried out as per the stipulations contained in various Sub-

Sections of these specifications and the latest Indian Standards, Acts, Codes and best practices.

iii) In case of conflict between the stipulations contained in various Sub-Sections of

these specifications and stipulations of Indian Standards, Codes, etc., the requirements of stipulations contained in various Sub-Sections of these specifications, shall prevail over that of Indian Standards, Codes, etc.

iv) Some of the applicable Indian Standard Codes, etc. are referred to here below:

IS: 73 Specification for paving bitumen.

IS: 226 Specification for structural steel (standard quality).

IS: 269 Specification for Ordinary Portland cement, 33 grade.

IS: 280 Specification for mild steel wire for general engineering

purposes.

IS: 383 Specification for coarse and fine aggregates from natural sources for concrete.

IS: 432 Specification for mild steel and medium tensile steel bars and (parts I & II) hard drawn steel wire for concrete reinforcement.

IS: 455 Specification for Portland slag cement.

IS: 456 Code of practice for plain and reinforced concrete.

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IS: 457 Code of practice for general construction of plain & reinforced

concrete for dams & other massive structures.

IS: 516 Method of test for strength of concrete.

IS: 650 Specification for standard sand for testing of cement.

IS: 702 Specification for industrial bitumen.

IS: 816 Code of practice for use of metal arc welding for general construction in mild steel.

IS: 1199 Methods of sampling and analysis of concrete.

IS: 1200 Method of measurement of building and civil engineering works.

(Part-II, V, VIII, water proofing and damp proofing. XVIII)

IS: 1367 Technical supply conditions for threaded steel fasteners.

IS: 1489 Specification for Portland-Pozzolana cement. (Part-I) Fly ash based. (Part-II) Calcined clay based. IS: 1566 Specification for Hard-drawn steel wire fabric for concrete

reinforcement.

IS: 1609 Code of practice for laying damp proof treatment using bitumen felts.

IS: 1786 Specification for high strength deformed steel bars and wires for

concrete reinforcement.

IS: 1791 General requirements for batch type concrete mixers.

IS: 1838 Specification for preformed fillers for expansion joints in concrete (Part-l)pavements and structures (non-extruding and resilient type).

IS: 2204 Code of practice for construction of reinforced concrete shell

roof.

IS: 2210 Criteria for the design of reinforced concrete shell structures and folded plates.

IS: 2386 Methods of test of aggregates for concrete. (Parts I to VIII)

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IS: 2438 Specification for roller pan mixer.

IS: 2502 Code of practice for bending and fixing of bars for concrete reinforcement.

IS: 2505 General requirements for concrete vibrators, immersion type.

IS: 2506 General requirements for concrete vibrators, screed board type.

IS: 2514 Specification for concrete vibrating tables.

IS: 2571 Code of practice for laying in-situ cement-concrete flooring. IS: 2645 Specification for Integral cement water proofing compounds.

IS: 2722 Specification for portable swing weigh batchers for concrete.

(single and double bucket type)

IS: 2750 Specification for Steel scaffoldings.

IS: 2751 Code of practice for welding of mild steel plain and deformed bars for reinforced concrete construction.

IS: 3025 Methods of sampling and test waste water.

IS: 3067 Code of practice for general design details and preparatory work

for damp proofing & water proofing of building.

IS: 3150 Specification for hexagonal wire netting for general purposes.

IS: 3366 Specification for Pan vibrators.

IS: 3370 Code of practice for concrete structures for the storage of liquids. (Part I to IV)

IS: 3384 Specification for bitumen primer for use in waterproofing &

damp proofing.

IS: 3414 Code of practice for design and installation of joints in the buildings.

IS: 3550 Methods of test for routine control for water used in industry.

IS: 3558 Code of practice for use of immersion vibrators for consolidating

concrete.

IS: 3696 Safety code for scaffolds and ladders. (Part I & II)

IS: 4014 Code of practice for steel tubular scaffolding.

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(Parts I & II)

IS: 4031 Methods for physical tests for hydraulic cement.

IS: 4130 Safety codes for demolition of buildings.

IS: 4326 Code of practice for earthquake resistant design and construction of buildings.

IS: 4461 Code of practice for joints in surface hydro-electric power

stations.

IS: 4656 Specification for form vibrators for concrete.

IS: 4925 Specification for batching and mixing plant.

IS: 4990 Specification for plywood for concrete shuttering work.

IS: 4995 Criteria for design of reinforced concrete bins for the storage of (Parts I & II ) granular and powdery materials.

IS: 5121 Safety code for piling and other deep foundations.

IS: 5256 Code of practice for sealing joints in concrete lining on canals.

IS: 5525 Recommendations for detailing of reinforcement in reinforced

concrete work.

IS: 5624 Specification for foundation bolts.

IS: 6461 Glossary of terms relating to cement concrete.

IS: 6494 Code of practice for water proofing of underground water reservoirs and swimming pools.

IS: 6509 Code of practice for installation of joints in concrete pavements.

IS:7193 Specification for glass fiber base coal- tar pitch and bitumen felts.

IS: 7293 Safety code for working with construction machinery.

IS: 7861 Code of practice for extreme weather concreting. (Parts I & II)

IS: 9012 Recommended practice for shotcreting.

IS: 9103 Specification for admixtures for concrete.

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IS: 9417 Recommendations for welding cold-worked steel bars for reinforced concrete construction.

IS: 9595 Recommendations for metal-arc welding of carbon and carbon

manganese steels.

IS: 10262 Recommended guidelines for concrete mix design.

IS: 11384 Code of practice for composite construction in structural steel and concrete.

IS: 12118 Specification for two-part polysulphide.

IS: 12200 Code of practice for provision of water stops at transverse

contraction joints in masonry and concrete dams. IS:8112 High strength ordinary Portland cement. (Grade 43)

IS: 12269 53 Grade ordinary Portland cement.

IS: 12600 Portland cement, low heat.

SP: 23 Handbook of concrete mixes.

SP: 24 Explanatory Handbook on IS: 456-1978.

SP: 34 Handbook on concrete reinforcement and detailing.

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5.0.4 TECHNICAL REQUIREMENTS – INSTALLATION

For technical requirement of mixing / fabrication and laying / installation / erection of Cast-in-Situ Concrete and allied works, refer to each Sub-Section of this section of technical specification.

5.0.5 SAMPLING, TESTING AND QUALITY ASSURANCE

i) Facilities required for sampling materials, concrete, reinforcement formwork, etc. in the field and in the laboratory shall be provided by the Contractor. The Contractor shall carry out all sampling and testing in accordance with the relevant Indian Standards and/or International Standards, this specification and approved field quality plan. Where no specific testing procedure is mentioned, the tests shall be carried out as per the prevalent accepted engineering practice to the directions of the Engineer / Purchaser. Tests shall be done in the field in the presence of the Engineer / Purchaser or his authorised representative and at a laboratory, approved by the Engineer / Purchaser, and the Contractor shall submit to the Engineer / Purchaser the test results in triplicate within three days after completion of any test or as directed by the Engineer / Purchaser.

ii) The Contractor shall maintain records of all inspection and testing, which shall be

made available to the Engineer / Purchaser. The Engineer / Purchaser, at his discretion, may waive some of the stipulations for small and unimportant concreting operations and other works.

iii) Work, found unsuitable for acceptance, shall be removed and replaced by the

Contractor. The work shall be redone as per specification requirements and to the satisfaction of the Engineer / Purchaser at no extra cost to the Purchaser.

5.0.5.1 Quality Assurance Programme

i) The Contractor shall submit and finalise a detailed field Quality Assurance Programme within 30 days from the date of award of the contract, before commencement of work at site, according to the requirements of the specification. This shall include setting up of a testing laboratory, arrangement of testing apparatus / equipment, deployment of qualified / experienced manpower, preparation of format for record, field quality plan, etc. On finalised field quality plan, the Purchaser shall identify customer hold points, beyond which work shall not proceed without written approval from the Engineer / Purchaser. The testing apparatus / equipment installed in the field laboratory shall be calibrated/corrected by the authorised persons, recommended by the Manufacturer or as required, to give accurate testing results.

ii) Frequency of sampling and testing, etc. and acceptance criteria are given in Table

1. However, the testing frequencies set forth are the desirable minimum and the Engineer / Purchaser shall have the full authority to call for additional tests as frequently as he may deem necessary to satisfy himself that the material and works comply with the appropriate specifications.

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TABLE 1

FREQUENCY OF SAMPLING AND TESTING

SR.NO.

Nature of test/ Characteristics

Method of Test No. of samples & frequency of Test

Remarks

I COARSE AGGREGATES

a) Particle size and shape

IS: 2386(Pt.1) One per 100 Cu.m. or part thereof or change of source whichever is earlier

Results to be as per the requirement of design mix, subject to variations within the limits specified in relevant Indian Standards.

b) Moisture content IS: 2386(Pt.3) 2 days Once for each stack of 100 Cu.m. of part thereof except during monsoon when this has to be done every day before starting of the work.

Accordingly, water content of the concrete shall be adjusted.

c) Specific gravity, density, voids absorption.

IS: 2386(Pt.3) 7 days Once in 12 weeks or change of source, whichever is earlier.

These tests shall be carried out while establishing design mix and results to be intimated.

d) Mechanical properties, crushing value, abrasion value and impact value.

IS: 2386(Pt.4) Initial stage only Once per source

Acceptance norms shall be as per IS: 383.

e) Soundness IS: 2386(Pt.5) Once per source Acceptance norms shall be as per IS: 383.

f) Reaction with alkali IS: 2386(Pt.7) Once per source These tests shall be carried out while establishing design mix and result to be intimated. Acceptance shall be as per IS: 2386(Pt7.)

g) Flakiness and petrographic

examinations

IS: 2386 This is to be done once and should be repeated in case

These tests shall be carried out while establishing design mix

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SR.NO.



Remarks

the source is changed

and results to be initiated

h) Deleterious materials

IS: 2386(Pt.2) Daily Once per source

Results should be within the limit as specified in relevant Indian Standard and in this specification.

II. FINE AGGREGATES / SAND

a) Particle size and shape.

IS: 2386 (Pt.1) One per 100 cu. m. or part thereof or change of source, whichever is earlier.

Should be as per the requirement of design mix, subjected to variation within the limit as specified in relevant IS code.

b) Specific gravity, density, voids, absorption and bulking.

IS: 2386 (Pt.3) 7 days Once in 12 weeks or change of source whichever is earlier.

These tests will be carried out while establishing design mix and results to be intimated.

c) Bulkage, moisture content (Routine test)

IS::2386 (Pt.3) 2 days To be done every day before start of work.

Volume of sand and weight of water shall be adjusted as per Bulkage and moisture content.

d) Silt, clay, deleterious materials, organic impurities.

IS: 2386 (Pt.2) Daily Once per source to be repeated, if source is changed.

Acceptance norms shall be as per IS: 383.

e) Soundness and Petrographic examination.

IS: 238 (Pt. 5 & 8)

Once per source Acceptance norms shall be as per IS: 383.

f) Mortar making properties.

IS: 2386 (Pt.6) Once per source Acceptance norms shall be as per IS: 383.

g) Reaction with alkali.

IS: 2386 (Pt.7) Once per source Acceptance norms shall be as per IS: 383 and IS: 2386(Pt.7)

III. CEMENT

h) Setting time. IS: 4031 One sample of each received from

Acceptance norms shall be as per relevant Indian

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SR.NO.



Remarks

stores. Standards.

i) Compressive strength.

IS: 4031 One sample of each received from stores.

Acceptance norms shall be as per relevant Indian Standards.

IV. WATER

Harmful substances, pH value, initial setting time, compressive strength.

IS: 3025, IS: 4031& IS: 516

Once a month for each source.

Acceptance norms shall be as per Clause 5.4 of IS: 456

V. CONCRETE

j) Workability (Slump and compaction factor).

IS: 1199 One sample every two hours from every fixing plant.

Acceptance value shall be as per Clause 7.1 of IS: 456

k) Crushing strength IS: 516 iii) As per Clause 15.2.2 of IS: 456 for initial period.

Acceptance criteria shall be as per Clause 16 of IS: 456.

iv) One sample of six cubes per 150 cu. m. or part there of mass concrete for subsequent period.

A minimum of 3 specimens shall be tested for 28 days strength.

l) Water Cement Ratio.

IS: 1199 At random at the time of batching.

According to mix design.

m) Cement content IS: 1199 At random at the time of batching

According to mix design.

n) Water tightness test for (water retaining structures)

IS: 3370 Each tank or reservoir.

Acceptance criteria as per specification.

o) Finished Physical All structures Acceptance as per

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SR.NO.



Remarks

dimensions measurement Specifications.

V1. FORM WORK

p) Staging (Durability, strength & soundness of staging, joints, adequacy of its foundation and specific level)

Visual Each member Any staging intended for use shall be approved by the Engineer / Purchaser for its durability and strength.

After erection of staging, nominated representatives of Engineer / Purchaser shall check the soundness of the staging as a whole, its joints, adequacy of its foundation and the specific levels.

q) Shuttering

v) Materials Visual Random Formwork materials shall be strictly as per specifications and approval of the Engineer / Purchaser. Materials for formwork shall be unwrapped, thoroughly clean and without broken or damaged edges either due to repetitive use or otherwise. Oiling of formwork before concreting shall be resorted to.

vi) Joints Visual Random Joints shall be leak-proof to avoid loss of liquid.

vii) Dimensions and plumb

Physical measurement

Each member and before every lift.

Tolerance as per Specification.

VII REINFORCEMENT

r) Placement Visual each The bar bending schedule with the necessary hooks, laps, covers, spacers and

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SR.NO.



Remarks

chairs shall be 100% checked for all concreting works before start of work.

s) Cutting tolerance Physical measurement

Random Tolerance shall be as per specification.

t) Freedom from defects

Visual Random Any of the bars selected for use shall be free from cracks, surface flaws, laminations and rough, jagged and imperfect edges.

VIII EMBEDDED PARTS

u) Type of embedment

Visual Each part Type/Details shall drawings. Tolerance as per specifications.

v) Location and Physical Each part Details as per drawings. Tolerance as per specifications.

5.0.6 RATES AND MEASUREMENTS

The clauses of rates and measurements mentioned in all Sub-Sections of this specification shall apply for item rate contracts only. These shall not be applicable to turnkey and/or lump sum contracts. However, for reconciliation of Purchaser issue materials (if any), for such turnkey and/or lump sum contracts, all the relevant clauses of measurements mentioned in relevant sections of these specifications shall be applicable. For determining the quantities of work below ground level, final graded ground or plinth level, whichever is applicable, shall be the determining factor. Accordingly, RCC trench, pedestal, plinth beam etc., which are partly above ground shall be considered as below ground level work.

5.0.6.1 Rates

i) The items of work in the Schedule of Items describe the work in brief. The various items of the Schedule of Items shall be read in conjunction with the corresponding Sub-Sections in these Technical specifications including amendments and addition, special conditions of contract and other tender documents, if any. For each item in the Schedule of Items, the Contractor rates shall include for the activities covered in the description of the item as well as for all necessary operations described in the specification.

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ii) The Contractor's quoted rates shall include minor details which are obviously and fairly intended, and which may not have been included in the description of these documents, but are essential for the satisfactory completion of the work. Quoted rates shall also include for all safety measures as required by codal provisions, local regulations etc., and for execution to the satisfaction of the Engineer / Purchaser.

iii) The Contractor's quoted rate for each item shall be inclusive of providing all plant,

equipment, labour, engineering supervision and technical personnel, materials, transportation from stores, staging and all temporary works. Skilled and unskilled labour, works / activities / operations stipulated in the schedule of items, specification, drawings and for all leads and lifts.

iv) The Contractor's quoted rates shall also include for all Quality Assurance

requirements such as, but not limited to, providing for Engineer / Purchaser's inspection, testing samples, transport of samples to laboratory, testing, maintaining and submitting all test and inspection records, etc.

5.0.6.2 Measurements

i) All measurements shall be in SI units.

ii) Linear measurements shall be in meters (m) correct up to second place of decimal. Areas and Volumes shall be calculated from the linear measurements and shall generally be in sq. meters (Sq.m) and cubic meters (Cu.m.) respectively, rounded off to two decimal places. For rounding off, values in the third decimal place, which are below 5 shall be ignored and those 5 and above shall be taken as 10.

iii) For each item of work, the total quantity for payment, at quoted rates, shall be the

lesser of actual quantity executed and that evaluated on the basis of mode of measurements given subsequently. In case of part acceptance of work, the Engineer / Purchaser shall have the authority to withhold a part of the payment.

iv) All measurements shall be either jointly recorded by the Contractor and the

Engineer / Purchaser or as per the design drawings, whichever is less. However the decision of the Engineer / Purchaser shall be the final and binding to the Contractor in this regard. Below ground and above ground works, shall be measured separately, wherever specified in the Schedule of items. For determining the below or above ground works, formation level or plinth, whichever is applicable, shall be the governing factor. (e.g., the protruding portion of trench shall be considered as below ground work, whereas RCC floor slab at plinth level shall be considered as above ground work).

SUB SECTION - I

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CAST-IN-SITU CONCRETE

3.1.0 5.1.1 INTENT

This Sub-Section of the specification deals with plain or reinforced cement concrete for general use and in structures and covers the requirements for concrete, materials, their properties, storage, handling, grading, mix design, strength and quality, pouring at all levels, testing, casting, protecting, curing, finishing, etc.


i) This part of the specification covers the requirement for plain and or reinforced cement concrete for all kinds of work such as building up of piles, pilecap, foundations including machine foundations, pedestals, columns, beams, slabs, lintels, floors, roofs, parapets, facia, flooring, under bed, screed concreting, concreting over metal decking, encasement of structures, area paving, trenches, drains, pits, sumps, rigid foundation for rail-tracks, manholes, culverts, walls, tanks, coping, jambs, waist slabs, soffits of stairs, risers, treads, canopy, portico, grade slab, decks supported on vibration isolation system, basement, cable vault, etc.

ii) For the concreting work in piling, specification for concreting as specified under

piling chapter shall also be referred to in addition to the specification covered herein. In case of conflict between stipulation in piling chapter and this chapter, the specification covered under piling chapter shall prevail.

iii) The provisions of IS: 456 shall be followed as general guidance, along with all

other relevant Indian Standards, unless otherwise specifically mentioned. Contractor shall deploy mechanised system for production, transportation and placement of concrete.

iv) At least one week before commencing the construction of any large concrete

section, the Contractor shall submit, for approval of the Engineer / Purchaser, detailed proposals for placing the concrete to demonstrate the suitability of the methods.

5.1.2.1 MATERIALS

In general, all the materials used in the manufacture of concrete shall be in accordance with the Technical Specification for Properties, Storage and Handling of Common Building Materials, (Section 2), which shall be deemed to form a part of this specification.

The Engineer / Purchaser shall have the right to inspect the sources of materials, method of procurement and storage of materials, quality control procedures, etc.

A) Cement

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Ordinary Portland cement (Grade-43) conforming to IS: 8112 shall be used for all important and critical structural concreting works and the certificate of manufacturer shall be furnished with each batch. Special cement shall be used for underground structures if required as per approved soil report. Fly ash based Portland Pozzolana cement conforming to IS : 1489 (Part – 1) shall only be used for non – important structures after the approval of Owner/Consultant. Higher grade of Portland ordinary cement namely Grade 43 and Grade 53 conforming to IS : 8112 and IS : 12269 respectively can also be used for specific application. However, ordinary Portland cement shall necessarily be used for structures requiring grade of concrete of M30 and above.

B) Aggregates

i) Aggregates mean both coarse and fine inert materials used in the preparation of

concrete. Aggregates shall consist of natural sand and / or crushed stone from a source known to produce satisfactory aggregate for concrete and shall conform to IS: 383

ii) For reinforced concrete work, aggregates conforming to IS: 383 having a

maximum size of 20 mm shall be used. For certain reinforced concrete works, aggregates having a maximum size of 12.5 mm shall also be used. However, for lean concrete provided as mud mat below structural concrete, maximum size up to 40 mm shall be used.

iii) Petrographic examination of aggregate shall be carried out by the Contractor at

any of the approved laboratory to ascertain the structure and rock type including presence of strained quartz and other reactive minerals for machine foundations, etc., and other structures as specified in schedule of items. Moreover, in case, the coarse aggregate sample is of composite nature, the proportions (by weight) of different rock types in the composite sample and petrographic evaluation of each rock should also be ascertained. While determining the rock type, special emphasis should be given on identification of known reactive rocks like chalcedony, opal, etc. The Procedure laid down in IS: 2430 for sampling of aggregates may be followed.

iv) The laboratory test shall determine potential reactivity of the aggregate, which

may lead to reaction of silica in aggregate with the alkalis of cement and / or potential of some aggregates like limestone to cause residual expansion due to repeated temperature cycle. If the same is established, the contractor shall further carry out alkali aggregates reactivity test as per IS: 2386 (Part VII) and / or repeated temperature cycle test to establish the suitability of the aggregates for the concrete work. The test results, with final recommendations of the laboratory, as to a suitability of the aggregate, for use in the concrete work for various structures and suggested measures, in case of results are not satisfactory, shall be submitted to the Engineer / Purchaser for his review, in report form.

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v) In case in the report, it is established, than the aggregates contain reactive silica, which would react with alkalis of the cement, the contractor shall change the source of supply of the aggregate or take measures as recommended in the report as instructed by Engineer / Purchaser. In case aggregates indicate residual expansion, under repeated temperature cycle test (from 10 ºCelsius to 65 ºCelsius and for temperature cycles) the material shall not be used for concreting of TGs’, BFP’, Fans, mills and other equipment foundations which are likely to be subjected to repeated temperature cycle. The contractor shall use aggregates free from residual expansion under repeated temperatures cycle test.

C) Pozzolana (Fly Ash)

Fly ash based Portland Pozzolana cement conforming to IS: 1489 (Part- 1) shall only be used for

non important structures after the approval of Owner/Consultant. D) Admixtures

Admixtures in concrete for promoting workability, improving strength, entraining air for similar purposes may be used only after the written permission from the Engineer / Purchaser is obtained. These shall be free from, injurious amount of chloride, etc. Addition of admixtures should not reduce the specified strength or durability of concrete and should not have detrimental effect on reinforcement. The admixtures shall conform to IS: 9l03 and shall be of proven make and from a reputed manufacturer. Calcium chloride as accelerating admixture is not permitted to be used other than in mass concrete works. The Contractor shall produce latest test results carried out at approved Government Test Houses for the approval of the Engineer / Purchaser, before use. Details of admixtures have been covered under Sub-Section - X.

E) Water

i) Water used for mixing and curing shall be clean and free from injurious amounts of

oils, acids, alkalis, sugar, organic materials, or other substances that may be deleterious to concrete or steel. Potable water i.e. generally considered satisfactory for mixing concrete. The maximum permissible values of impurities shall be as given in Clause 5.4 of IS: 456.

ii) In case of doubt regarding development of strength. the suitability of water for

making concrete shall be ascertained by the compressive strength and initial setting time tests specified in IS: 456.

iii) Average 28 days compressive strength of at least three 150mm concrete cubes

prepared with water proposed to be used shall not be less than 90% of the average strength of three similar concrete cubes prepared with distilled water. The cubes shall be prepared, cured and tested in accordance with IS: 456.

iv) The initial setting time of test block made with the appropriate cement and the

water proposed to be used shall not be less than 30 minutes and shall not differ

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by ± 30 minutes from the initial setting time of control test block prepared with the same cement and distilled water. The test blocks shall be prepared and tested in accordance with the requirements of IS: 4031 (Part5).

v) Where concrete, made from water, proposed to be used does not satisfy the

above requirements and/or contains an excess of acid. alkali, sugar, salt or other deleterious, substances, then the Engineer / Purchaser may refuse to permit its use. Sea water shall not be used for curing besides mixing in concrete.

F) Grades of Concrete

All concrete shall be "design mix concrete” as defined in IS: 456, unless a nominal mix concrete such as 1:2:4, 1:3:6, 1:4:8 or 1:5:10 proportion is specified. The proportion referred to is by weight (mass). The grades for 'design mix' concrete shall be designated M15, M20, etc. as specified in IS: 456.

A screed layer not less than 100 mm thick of cast in situ concrete of nominal mix 1:3:6 shall be provided below all water retaining structures. Minimum 75mm thick layer of 1:4:8 proportion concrete shall be applied below brick wall foundations, RCC foundations, trenches and underground structures.

Plinth protection work around buildings shall be constructed in M20 grade concrete.Base plate encasement, All RCC paving work, Precast concrete work, ground floor slabs, cable and pipe trenches, encasement of structural steel work, etc. shall be constructed in M25 grade concrete.

For all RCC members such as Foundation and super structure, grade beams, pedestals, columns, roof slabs, Water retaining structures below and above ground, , etc. M30 grade concrete shall be used.

i) Nominal mix Concrete

Nominal mix shall conform to Clause 9.3 of IS: 456. Nominal mix concrete shall be used only for plain Cement concrete works and where shown on drawings or specifically allowed by the Engineer / Purchaser. Such concrete shall not require preparation of trial mixes and all such concrete shall be mixed in a mechanical mixer. Proportions for nominal mix concrete shall be according to Table-9 (Clauses 9.3 and 9.3.1) of IS: 456. In addition, standard proportion by volume shall he used wherever specified.

In proportioning concrete, the cement shall be measured by (mass) weight. The quantities of fine and coarse aggregates may be determined by volume (for corresponding weight) but preferably by weight. If fine aggregates are moist, the amount of surface water shall be determined. Also an allowance shall be made for bulking in case of volume batching, in accordance with IS: 2386 (Part-III). Allowance shall also be made for surface water present in the aggregates, when computing the water requirement. All the above data shall be maintained properly, to the satisfaction of the Engineer / Purchaser.

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The recommended maximum water cement ratios are specified in Table 2.

TABLE 2

RECOMMENDED WATER-CEMENT RATIO Nominal mix concrete per bag

of 50 Kg cement (max.) Quantity of water

1:5:10 60 liters

1:4:8 45 liters

1:3:6 34 liters

1:2:4 32 liters

ii) Generally as broad guidelines, the strength requirements of Nominal mix

concrete 1:5:10 shall correspond to grade M5, 1:4:8 shall correspond to grade M7.5, 1:3:6 to grade M10 and 1:2:4 to grade M15 of IS: 456.

iii) If Nominal mix concrete made in accordance with specified proportions does

not yield the specified strength of the corresponding grade and fails to satisfy the requirements of "acceptance criteria for concrete" as specified in IS: 456. Such concrete shall be treated in the following manner:

In case the Engineer / Purchaser is satisfied that lower strength of concrete is attributed to material and workmanship of the Contractor, then such concrete shall be replaced by concrete of specified strength. The Engineer / Purchaser may, however, also accept such lower strength concrete but such lower strength concrete shall be classified as belonging to the appropriate lower grade proportion for measurement and payment.

In case the Engineer / Purchaser is satisfied that lower strength of concrete is not attributable to the Contractor, he may direct in writing to increase the cement content to obtain specified strength. Such extra cement shall also be considered for reconciliation purposes. The use of richer mix shall be continued until the Engineer / Purchaser instructs otherwise.

iv) Nominal mix proportion shall not be classified as higher grade proportion either

on the ground that the test strengths are higher than the minimum specified or in the case where the Engineer / Purchaser directs use of additional cement over the quantity specified for the particular mix proportion to achieve the minimum specified strength.

5.1.2.2 Design Mix Concrete

i) Design Mix Concrete shall be used on all concrete works, except where specified otherwise or specially permitted by the Engineer / Purchaser. The mix shall be designed for all grades of concrete (except those specified under Nominal Mix Concrete) such as to obtain the required workability and the characteristic strength not less than the appropriate values given in Table 3 of Section 3. Using Standard

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Deviation specified in IS: 10262 corresponding to good quality control, the Minimum value of target strength of design mix of various grades of concrete shall be as per Table 3 of Section 3.

ii) However, the Engineer / Purchaser may allow, to change the target strength values

based on adequate numbers of works test results.

TABLE 3

GRADES OF CONCRETE

Grade Designation of concrete Compressive strength of a 15 cm cube at 28 days (N/Sq.m)

Preliminary test strength (target strength of trial mix)

Characteristic strength on works cubes

M 15 20.8 15 M 20 27.6 20 M 25 33.7 25 M 30 39.9 30 M 35 45.4 35

iii) In proportioning concrete, the quantity of both cement and aggregates shall be

determined by mass. However, only in some exceptional cases including concreting in some isolated areas, the Engineer / Purchaser may allow the quantity of aggregates to be determined by an equivalent volume basis after the relationship between weight and volume is well established by trials and the same shall be verified frequently. Water shall be either measured by volume in calibrated tanks or weighed. All measuring equipment at site, shall be maintained in a clean and serviceable condition, and their accuracy shall be periodically checked and shall conform to Clause 10.2.2 of IS: 456

iv) To keep the water-cement ratio to the designed value, allowance shall be made for

the moisture contents in both fine and coarse aggregates and determination of the same in accordance with IS: 2386 (Part -III) shall be made as frequently as directed by the Engineer / Purchaser.

v) In the structures where the impermeability and shrinkage of concrete have an

important bearing on the durability and serviceability of the structures, such as water retaining structures, basements, underground premises, tunnels, pump houses, pre-stressed structure, thin precast members etc. the water cement ratio shall be kept low and preferably not exceeding 0.45.. To increase the workability, Plasticiser may have to be used in such cases. Trial mix shall be carried out accordingly.

vi) With the permission of the Engineer / Purchaser, for any of the above mentioned

grades of concrete, if the water quantity has to be increased, proportionately cement quantity shall also be increased, to keep the ratio of water to cement same as adopted

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in Preliminary tests for the corresponding grade of concrete. The extra cement required on account of this shall also be considered for reconciliation purposes.

5.1.2.3 Mix Design

i) IS: 10262 shall be followed as general guidance for mix design. Preliminary tests/trial mix, as specified or as required by the Engineer / Purchaser, shall be carried out sufficiently ahead of the actual commencement of the work with different grades of concrete made from representative samples of aggregates and cement expected to be used on the works. These tests are to be conducted to arrive at the grading of aggregates, water-cement ratio, workability and the quantity of cement required to give preliminary (target) compressive strengths as specified in Table 3 in Clause No. 3.1.2.2 of Sub-Section – I of Section 3 of this specification.

ii) Minimum cement contents from durability consideration, different exposures and

sulphate attack shall be as given in Table-4 (Clauses 8.2.2.4 and 9.1.2) of IS: 456. In case, higher value is obtained from trial mix from strength consideration, same shall be provided.

iii) At least four trial mixes are to be made and minimum nine test cubes taken for each

trial mix noting the slump for each type of mix. The cubes shall then be properly cured and three cubes for each mix shall be tested in a laboratory (approved by the Engineer / Purchaser) at 7 days and others at 28 days for obtaining the compressive strength. The test reports shall be submitted to the Engineer / Purchaser. The design mix particulars shall indicate with the help of graphs and curves etc. the extent of variation in the grading of aggregates, which can be allowed. While designing mixes, over wet mixes shall be avoided.

iv) The Contractor shall submit the test reports of mix design to the Engineer /

Purchaser for his review, indicating design criteria, analysis and proportioning of materials, etc. On the basis of the above test reports, a mix proportion by mass and the water-cement ratio, shall be determined by the Contractor such that concrete prepared with this mix will yield the desired characteristic strength and shall have suitable workability. The mix design to be adopted on the works shall be subject to the approval of the Engineer / Purchaser.

v) The proportions, once decided for different grades of concrete, shall be adhered to,

during all concreting operations as long as the quality of the materials does not change. If, however, at any time, the quality of materials being used has changed from those for Preliminary mix design, or there is a change either in the required strength of concrete, or water-cement ratio or workability, the Contractor shall have to make similar trial mixes and perform initial tests to ascertain the revised mix proportions and water-cement ratio to be used for obtaining the desired strength and consistency.


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For applicable codes and standards, refer to Clause no. 3.0.3 of Section – 3 of this specification, in addition to the Codes and Standard mentioned at various places under this Division.

5.1.4 TECHNICAL REQUIREMENTS - INSTALLATION 5.1.4.1 Workability of Concrete

i) The workability of concrete shall be checked at frequent intervals. The workability of concrete measured in accordance with IS: 1199 for every sample taken for testing shall be recorded with the corresponding cube test result and shall conform to Clause 7.0 of IS: 456.

ii) The degree of workability necessary to allow the concrete to be well compacted and

to be worked into the corners of formwork and round the reinforcement to give the required surface finish shall depend on the type and nature of the structure and shall be based on experience and tests. The suggested ranges of values of workability for concrete for some placing conditions, measured in accordance with IS: 1199 and as stipulated under Clause 7.0 of IS: 456, are given below in Table-4 for guidance only. In addition, in some special cases like casting of pile, very high degree of workability (up to 180 mm slump) shall be used.

TABLE-4

LIMITS OF WORKABILITY

Placing Conditions Degree of

Workability Slump (mm)

Large mass concrete structure with heavy compaction equipment, roads and the like.

Very low 0-25

Uncongested wide and shallow R.C.C structures

Low 25 – 50

Deep but wide R.C.C structures with congestion of reinforcement and inserts

Medium

25-75 Very narrow and deep R.C.C structures with congestion due to reinforcement and inserts

High 75 – 125

Note:

Notwithstanding, the values given above, the slump to be maintained for work in progress shall be as per directions of the Engineer / Purchaser.

5.1.4.2 Mixing of Concrete.

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i) All structural concrete mixing shall be done at a single central batching plant, conforming to IS: 4925, situated within the area allocated for the Contractor's particular use as shown on the drawing or as directed by the Engineer / Purchaser. The plant shall have a mechanically operated mixer of an approved size, capacity not less than 1 (one) cubic meter and type, capable of ensuring a uniform distribution of the materials throughout the mass and the mass is uniform in colour and consistency. In case the contractor is procuring ready mix concrete from approved batching plant, the same has to be approved from Engineer / Purchaser. Digitized recording of the material consumed along with the quantity of concrete produced for every shift of eight hours shall be submitted to the Engineer / Purchaser.

ii) However, for PCC work upto M15 Engineer / Purchaser may permit the use of

independent mechanical mixer with weigh conforming to IS: 1791 batching machine

iii) Water shall not be added into the drum of the mixer, until all the cement and aggregates constituting the batch are already in the drum and dry mixed for at least one minute and are uniformly distributed. Water shall then be added and mixing of each batch shall be continued until there is an uniform distribution of the materials and the mass but in no case shall mixing be done for less than two minutes and for at least 40 revolutions after all the water and materials are in the drum. When absorbent aggregates are-used or when the mix is very dry, the mixing time shall be extended as directed by the Engineer / Purchaser. Mixers shall not be loaded above their rated capacity as this prevents thorough mixing. The entire contents of the drum shall be discharged before the ingredients for the next batch are fed into the drum. No partly set or remixed or excessively wet concrete shall be used and it shall be immediately removed from site. Each time if the work stops for more than 30 minutes, the mixer shall be thoroughly cleaned and when the next mixing commences, the first batch shall have 10% additional cement.

iv) In exceptional circumstances and/or work in remote areas, hand mixing may be

allowed by the Engineer / Purchaser, subject to adding 10% extra cement which shall be considered for reconciliation purposes. The mixing shall be carried out on watertight platform and mixing shall be continued till a uniform colour and consistency of the mix is achieved.

v) Partly set or excessively wet concrete shall not be used. No concrete shall vbe mixed

by hand. 5.1.4.3 Concrete Conveying

i) Concrete shall be handled and conveyed as rapidly as practicable, from the place of mixing to the place of final laying by Transit mixers or by other approved means, before the initial setting of the cement starts. Concrete shall be conveyed in such a way that there is no segregation or loss of any of the ingredients and maintaining the required workability. If segregation occurs during transport, the concrete shall be remixed. During very hot or cold weather, if directed by the Engineer /

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Purchaser, concrete shall be transported in deep containers, which will reduce the rate of water loss, by evaporation in hot weather and heat loss in cold weather, at no extra cost to the Purchaser. The concrete shall be placed and compacted within 90 minutes of the addition of water to the mix. Any concrete left unplaced after this time shall be rejected and removed from site.

ii) Conveying equipment of concrete shall be watertight, well maintained and

thoroughly cleaned. Chutes shall not be used for transport of concrete without the written permission of the Engineer / Purchaser. The chute, in case permitted to be used, shall be of such size and design as to ensure practically continuous flow. Slope of the chute shall be so adjusted that the concrete flow without the use of an excessive quantity of water and without segregation of its ingredients. The delivery end of the chute shall be as close as possible to the point of deposit.

iii) Concrete may be conveyed and placed at location of pour by mechanically operated

equipment, e.g. pumps or pneumatic placers with the written permission of the Engineer / Purchaser, who shall review the entire scheme for which comprehensive details shall be furnished by the Contractor.

5.1.4.4 Concrete Placing

i) Concrete shall be placed and compacted in its final position before the cement reaches the initial set and normally concrete shall be compacted in its final position within minutes of leaving the mixer. Concrete shall be placed in the forms as close as possible to its final position in a single operation to the full thickness of slabs and beams and shall be placed in horizontal layers, not exceeding 2.5 m height in a single pour in walls, columns and similar members.

ii) Where direct placement is not possible, the Contractor shall provide suitable

arrangements such as chutes, tremie, elephant trunks, etc. to confine the movement of concrete as directed by the Engineer / Purchaser. Concrete shall not be dropped from a height or handled in a manner which may cause segregation. Also, concrete shall not be dropped from a height exceeding 1.5 metres. Trunking and chutes to owner/consultant’s approval shall be used for any concrete to be deposited from a height exceeding 1.5 metres.

iii) If concrete is placed by pumping, the consistency shall be the minimum necessary

for such conveyance of concrete. Before commencement of regular pumping, the pipeline shall be lubricated by cement mortar (1:2) and once pumping commences, stoppages shall be avoided.

iv) Concrete shall not be placed in foundations on soft areas or where there is standing

water or debris. Such soft areas shall be removed and filled with 1:4:8/ 1:3:6 nominal mix concrete, as directed by the Engineer / Purchaser.

v) For rock surfaces, it shall be ensured that the rock is sound. On sloping rock faces,

rough steps or benches shall be formed and concrete shall not be placed on a sloping rock surface. Prior to pouring concrete, the rock surface shall be cleaned with a high

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pressure water and air jet and kept wet for three hours. Also, before placing concrete, water shall be removed from depressions, the rock surface shall be dried and a 10mm thick cement sand mortar (1:6) layer shall be placed into all crevices, cracks, depression, etc.

vi) The placing of concrete shall be a continuous operation with no interruption in

excess of 30 minutes between the placing of continuous portions of concrete. Concrete shall be placed in continuous horizontal layers of 150mm or higher thickness as directed by the Engineer / Purchaser and thoroughly compacted before placing next layer. The thickness of each layer shall be such that it will be deposited before the previous layer has stiffened. When placing concrete through reinforcing steel, care shall be taken to prevent segregation of the coarse aggregates.

vii) Approval by the Engineer / Purchaser of any of the materials and/or work as required

herein shall not relieve the Contractor of his obligation to produce finished concrete in accordance with the drawings and specifications. Slots, openings, holes, pockets etc. shall be provided in the concrete as directed by the Engineer / Purchaser.

viii) Slabs, beams and similar members shall normally be poured in one operation. In

special circumstances, with the approval of the Engineer / Purchaser, these can be poured in horizontal layers, but it must be ensured that the under layer is not already hardened. Bleeding of under layer, if any, shall be effectively removed. Moulding, throating, drip course, etc. shall be poured as shown on the drawings or as desired by the Engineer / Purchaser.

ix) Compaction of concrete shall conform to Clause 13.3 of IS: 456. After the concrete

has been placed, it shall be spreaded and thoroughly compacted by approved mechanical vibrators to a maximum subsidence without segregation and thoroughly worked around reinforcement or other embedded fixtures into the correct form and shape. Hand tamping in some cases may be allowed subject to the approval of the Engineer / Purchaser. Care must be taken to ensure that the inserts, fixtures, reinforcement and formwork are not displaced or disturbed during placing of concrete.

x) Whenever vibration has to be applied externally, the design of formwork and the

disposition of vibrators shall receive special consideration to ensure efficient compaction and to avoid surface blemishes. Surface vibrators and form attached vibrator shall not be permitted under normal conditions. Their use shall require written approval of the Engineer / Purchaser.

xi) Vibrators shall penetrate both the layer poured and the under layer to ensure good

bond and homogeneity and to prevent the formation of cold joints. Immersion vibrators shall not be allowed to come in contact with steel reinforcement after start of initial set. Also, they shall not be allowed to come in contact with forms or finished surfaces.

xii) Immersion vibrators shall have a 'no load' frequency, amplitude and acceleration as

per IS: 2505 depending upon the size of the vibrator Immersion vibrators shall be

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operated by experienced personnel. These vibrators shall be immersed not more than 450mm apart and withdrawn when air bubbles cease to come to the surface. Such vibrators shall in no case be used to push concrete inside the forms. Vibrators shall be withdrawn slowly to avoid formation of void inside concrete.

xiii) No concrete shall be placed in wet weather or on a water covered surface. If there

has been any signs of washing of cement or sand, the concrete shall be entirely removed immediately. Suitable precautions shall be taken in advance to guard against possible rains before leaving the fresh concrete unattended.

xiv) Mass concrete shall be poured in lifts not exceeding 1.0 m in height unless otherwise

indicated on drawings or as directed by the Engineer / Purchaser. Horizontal lift shall not be more than l50cm in thickness, according to provision of IS: 457.

xv) Formwork and reinforcement shall be approved in writing by the Engineer /

Purchaser before concrete is placed. Concrete shall be placed only after all preparations for casting have been approved by the Engineer / Purchaser and approval given to proceed with the casting in writing on pour card to be maintained by the Contractor for this purpose and to be submitted along with the Contractor’s bills.

Concrete, when deposited, shall have a temperature of not less than 5 ºCentigrade and not more than 40 ºCentigrade. When depositing concrete in very hot weather, precautions shall be taken so that the temperature of wet concrete does not exceed 40 ºCentigrade while placing. This shall be achieved by stacking aggregates under the shade and keeping them moist, using cold water, reducing the time between mixing by sprinkling water, starting curing before concrete dries out, etc. The maximum allowable temperature of any point within any cast element is 60°C. The maximum allowable differential temperature between any two points in the same element is 15°C. Additional temperature control measures during construction (such as the use of insulated formwork) will be required. However, before mixing/placing concrete, when the above temperature conditions vary on either side, approval of the Engineer / Purchaser shall be obtained for the method of execution. Where specified on the drawings, construction, expansion or contraction joints shall be provided and the concrete shall be poured continuously between two adjacent joints. No other joints than shown on the drawings shall be permitted. Stoppage (cold) joints formed between two concreting operations separated by more than 6 hours time shall be subject to the same treatment as the construction joints.

5.1.4.5 Protection and Curing of Concrete

i) Newly placed concrete shall be protected by approved means from rain, sun and wind. Concrete placed below ground level, shall be protected from falling earth, during and after placing. Concrete placed in ground containing any deleterious substances, shall be kept free from contact with such ground or with water draining from such grounds, during placing of concrete and for a period of at least three days or as otherwise instructed by the Engineer / Purchaser.

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ii) The ground water around newly poured concrete shall be kept down to an approved level by pumping or other approved of drainage. Adequate steps shall be taken to protect immature concrete from damage by debris, excessive loading, vibration, abrasion, mixing with earth or other deleterious materials, etc. that may impair the strength and durability of the concrete.

iii) Curing shall be done as per Clause 13.5 of IS: 456. As soon as the concrete has

hardened sufficiently, it shall be kept in a damp or wet condition by ponding or by covering with a layer of sacking, canvas, Hessian or similar materials and kept continuously wet for at least seven days after final setting. This period may be extended, at the discretion of the Engineer / Purchaser, up to fourteen days. Curing of vertical surfaces exposed to drying winds shall begin immediately after the concrete has hardened. Concrete slabs and floors shall be cured for the periods mentioned above by flooding with water of minimum 25mm depth.

iv) Approved curing compounds may be used in lieu of moist curing with the

permission of the Engineer / Purchaser. However, such permission may be granted only in specific cases. Such compounds shall be applied to all exposed surfaces of the concrete, as soon as possible after the concrete has set.

v) Quantity of water applied shall be such as to prevent erosion of placed concrete and

retain the surface of concrete in moist condition during the entire curing period.

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5.1.4.6 Construction Joints

i) Construction joints shall conform to Clause 13.4 of IS: 456. However, for water retaining structures, provision of IS: 3370 shall also be followed.

ii) When work has to be interrupted, the concrete shall be rebated and/or keyed at the

joint to such shape and size as may be required by the Engineer / Purchaser or as shown on the drawings. All vertical construction joints shall be made with stop boards which are rigidly fixed and slotted to allow for the passage of the reinforcing steel. In the case of water retaining structures, basements, tunnels, etc. water stop of approved material shall be provided, if so specified on the drawings or as directed by the Engineer / Purchaser.

iii) Construction joints shall be located as shown or described on the drawings. Where it

is not described, the joints shall be in accordance with the following guidelines.

In a column, the joints shall be formed about 75mm below the lowest soffit of the beams framing into it, including haunches, if any. In flat slab construction, the joint shall be 75 mm below the soffit of the column capital.

Concrete in a beam shall be placed throughout without a joint. If unavoidable, the joint shall be vertical and within the middle-third of the span. When a beam intersects a girder, the joints in the girder shall be given an offset equal to a distance twice the width of the beam and additional reinforcement provided for shear. The joints shall be vertical throughout the full thickness of the concrete member with suitable shear key wherever shown on the drawing.

A joint in a suspended floor slab shall be vertical at one quarter points of the span and at right angle of the principal reinforcement.

Construction joints in equipment foundations shall not be provided without specific concurrence of the Engineer / Purchaser.

Vertical construction joints in water retaining structures shall not be permitted unless shown on the drawings.

The maximum horizontal length of wall to be poured in one operation in any one direction is 7.5 metres. A period of 7 days to be allowed between adjacent pours except where water stops are provided when this can be reduced with Owner/Consultant’s approval. Alternatively a gap of 600 mm width shall be left between adjacent pours and filled after 7 days from the date of formation subject to Owner/Consultant’s approval.

However, if the Contractor desires any adjustments in the location of construction joints (to suit site conditions) from those shown on drawings or from those explained above, he shall obtain prior approval from the Engineer / Purchaser.

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i) Before fresh concrete is placed, the cement skin of the partially hardened concrete which was poured earlier shall be thoroughly removed and the surface made rough and aggregate exposed, by wire brushing, hacking, water jetting, air jetting or any other method as directed by the Engineer / Purchaser. The rough surface shall be thoroughly wetted for about 1/2 hour and shall be dried and coated with 10 to 15 mm thick layer of 1:1 freshly mixed cement and sand slurry. Special care shall be taken to see that the first layer of concrete placed after a construction joint is thoroughly rammed against the existing layer.

ii) In forming a joint, concrete shall not be allowed to slope away to a thin edge. The

locations of construction joints shall be planned by the contractor well in advance of pouring and they will have to be approved by the Engineer / Purchaser. The Contractor's proposals shall include at least the location of construction joints, the sequence of pouring, formwork details and their stripping times.

iii) For construction of wall kicker / subsequent pours, the sequence of operation shall

be as follows, When the concrete has not fully hardened, all laitance shall be removed by scrubbing the wet surface with wire or bristle brushes, care being taken to avoid dislodgement of particles of aggregate. The surface shall be wetted and all free water removed. The surface shall then be coated with neat cement slurry. On this surface, a layer of concrete of 150 mm in thickness/height (minimum) shall first be placed and shall be well rammed against old work, particular attention being paid to corners and close spots. Work, thereafter, shall proceed in the normal way. The minimum height of kicker, if used, shall be 70 mm and carefully constructed.

iv) For multiple lift work, a suitable time gap shall be maintained between the setting of

the earlier placed concrete and the commencement of next concrete pour. After depositing concrete in columns, piers or walls, a time gap of minimum 4 hours and preferably 24 hours shall be maintained before depositing concrete in beams, girders or slabs, supported thereon in order to avoid cracking due to settlement.

5.1.4.7 Work in Extreme Weather Conditions

During hot weather (atmospheric temperature above 40 degree centigrade) or cold weather (atmospheric temp at 5 degree centigrade and below) the concreting shall be done as per the procedures and precautions set out in IS: 7861 (Parts I and II).

5.1.4.8 Cleaning and Finishing of Concrete

i) All concrete surfaces shall have an even and clean finish free from honeycombs, air bubbles, fins or other blemishes, unmarred and reasonably smooth. The formwork joint marks on concrete work exposed to view shall be rubbed with Carborundum stone and defects patched up with a paste of cement sand mortar (1:2) and cured. The finish shall be made to the satisfaction of the Engineer / Purchaser. Concrete surfaces to be subsequently plastered or where brick work is to be built against item, shall be adequately hacked as soon as the form is stripped off so that proper bond can develop.

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ii) Immediately after removal of forms, the concrete shall be allowed to be inspected and defective areas as pointed out by the Engineer / Purchaser shall be removed partially or entirely as directed. Holes, left by form bolts, etc. shall be filled up and made good with cement sand mortar of approved mix. All superficial defects such as honeycombing, rough patches, etc. shall be similarly made good. If the defective area is at a vulnerable location, e.g., at the ends of beams & columns, etc. then it may be necessary to cut out the member completely or in part and reconstruct as directed by the Engineer / Purchaser. If epoxies have to be used, the same shall be subjected to the approval of the Engineer / Purchaser. Poured concrete affected by faulty formwork shall be removed totally and replaced. If so directed, the Contractor shall have to resort to grouting / shotcreting.

iii) A smooth finish shall be obtained with the use of forms having smooth and even

surfaces and edges. Panels and form linings shall be of uniform size and be as large as practicable and installed with closed joints. Upon removal of forms, the joint marks shall be smoothened off and all finishes, projections etc. removed leaving the surfaces reasonably smooth and unmarred.

iv) Where integral cement concrete finish is called for, the surface shall be compacted

and then floated and treated with a straight edge and any high and low spots eliminated. The work shall be carried out as per IS: 2571.

5.1.5 SAMPLING, TESTING AND QUALITY ASSURANCE 5.1.5.1 General

i) Concrete cubes for works tests shall be cured under normal site conditions. When in the opinion of the Engineer / Purchaser, extreme weather conditions prevail, then these may require curing under job conditions.

ii) For the purposes of statistical analysis, any substandard cube result, which in the

opinion of the Engineer / Purchaser, is due to improper sampling, moulding or testing shall be discarded and a dummy result shall he substituted. The value of a dummy result shall be equivalent to the average value of the cubes from the same grade of concrete tested immediately before and after the discarded result. The number of such substandard cubes shall not exceed 5%.

iii) If the strength of the cubes, for any portion of the concrete work, falls below the

compressive strength specified, the Engineer / Purchaser shall have the right to order a change in the proportions or the water content for the remaining portion of the structure.

iv) If the 'strength' of the works cured test cubes falls below the specified strength, the

Engineer / Purchaser shall have the right to direct the Contractor to follow, provisions for temperature and moisture control during the period of curing as necessary to secure the required strength and may require retest in accordance with the standard method of securing, preparing and testing specimens from hardened concrete for compressive and flexural strengths, or load tests to be made on the

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portion of the building so affected. All such tests shall be made at the Contractor's expense.

i) Unacceptable concrete work shall be dismantled by the Contractor and replaced by

fresh work, meeting the specification requirements. In the course of dismantling, if any damage is done to the embedded items or adjacent structures, the same shall be made good, by the Contractor to the satisfaction of the Engineer / Purchaser at no extra cost to the Purchaser. Only as a very special case and that too in non-critical areas, the Engineer /

Purchaser may accept concrete work which is marginally unacceptable as per the criteria laid down in IS: 456. For such accepted work, payment shall be made at a reduced rate prorata to the concrete cube strength obtained, against that stipulated.

Before placing concrete, the inside of forms shall be checked to ensure that they are clean and thoroughly wetted or adequately treated, so as to prevent absorption of water from the concrete.

ii) Ultrasonic pulse velocity test shall be carried out for the top decks and columns of

all machine foundations and TG deck & column & its substructure to ascertain the homogeneity and integrity of concrete. In addition, additional cubes (at the rate of one cube per 150 cum of concrete subject to a minimum of six cubes) shall be taken to carry out Ultrasonic Pulse velocity (UPV) testing on the cubes to serve as reference UPV values. Testing shall be done as per IS: 13311 (Part-1).

iii) Cutting core test shall be carried out and shall comply with the requirements of IS:516 or an approved equivalent standard.

iv) Gamma radiography testing shall be carried out in accordance with the requirement of IS:13311, part 1 or equivalent. The Contractor shall arrange for the specialized agency for conducting the test at his cost. The Contractor shall also arrange all the necessary facilities and arrangement for conducting the test at site in terms of access, scaffolding etc. In case of any defects, the Contractor shall rectify the same as below and as directed by the Engineer / Purchaser.

Cement grout – cement grouting shall be done in structures / foundations where large-scale voids or honeycombing are observed. The cement grout with non-shrink admixture and / or plasticizer shall be used. Water cement ratio needs to be controlled and it shall be preferably less than 0.5. Nipples shall be fixed in the locations where grouting has to be carried out. Cement grout shall be injected at a pressure of 2.5 to 3.0 Kg / Sq.cm.

Epoxy grout – epoxy grouting shall be carried out in critical locations from serviceability as well as structural point of view. In addition, this shall be carried out in locations where narrow passage is available for free flow of grout.

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v) Rebound hammer test shall be carried out for ascertaining the quality of concrete work, as directed by the Engineer / Purchaser.

vi) Test shall be conducted for the water tightness of the liquid retaining structures as

per lS: 3370 and IS: 6494. The details and sequence of tests shall be as given here under:

All arrangements, including supply of water for testing purposes, shall be kept ready when the tank is nearing completion.

Water supply to the tank shall be in stages of 300 to 450mm height in order to check the water tightness of the tank and location of leakage of various levels.

The permissible drop in level in 24 hours shall be 6 mm in case of covered reservoir/tank and 12 mm in the case of open reservoir/tank.

The leakage points shall be marked and separately treated during test condition or after dewatering.

The reservoir/tank shall be retested for water tightness after rectification, if desired.

vii) For basement type structures like cables vault, track-hopper, tunnel, neutralising

pit, etc. the contractor shall examine the water tightness against ingress of sub-soil water.

viii) Frequency of sampling and testing including the methods for conducting the tests

shall be as given in Table 1 in Clause 3.0.5 of Section 3. 5.1.5.2 Sampling of Concrete

Samples from fresh concrete shall be taken according to IS: 1199 and tested as per IS: 516.

Normally only compressive test shall be performed but the Engineer / Purchaser may require other tests to be performed in accordance with IS: 516.

A) Trial Mixes:

At least four trial mixes for each grade of concrete shall be made with minimum 6 test cubes for each mix.

B) Works Tests:

The min. frequency of sampling of concrete of each grade shall be according to Clause 15.2.2 of IS: 456. However, after getting continuous satisfactory results and in the case of voluminous concrete works, the Engineer / Purchaser may at his discretion reduce the frequency of sampling as follows.

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For each grade of concrete and for each 8 hours (shift) of work or part thereof, at least one sample consisting of six specimens shall be taken from each 150 Cum. of concrete or part thereof, 3 specimens shall be tested at 7 days and remaining 3 shall be tested at 28 days. However in all cases, the 28 days compressive strength shall alone be the criterion for acceptance or rejection.

To control the consistency of concrete from every mixing, slump tests and compaction factor testes in accordance with IS: 1199 shall be carried out by the Contractor every two hours or as directed by the Engineer / Purchaser. Slumps corresponding to the test specimens shall be recorded for reference.

The strength of sample shall be the average of the strength of three specimens. The individual variation should not be more than 15% of the average.

Unless otherwise specified, the tolerance in construction shall be as follows:

Description of Item/ Structural element Permissible Deviation in mm

The dimensions of concrete as cast when compared with those on the drawings shall be within the tolerance given below: Faces of concrete in foundation and structural members against which backfill is placed.

+25 -10

Location of footing (for RCC framed structures only) +25 -25 Eccentricity of footing 2% of footing width of direction of

misplacement but limiting to 50 mm. Top surfaces of slabs and of concrete to receive base plates to be grouted.

+5 -5

Alignment of beams, lintels, columns, walls, slabs and similar elements.

+5 -5

Cross dimensions of wall, slabs and similar structural elements.

+5 -5

Deviation from specified dimensions of cross-section of columns and beams.

+12 -6

Alignment of holding down bolts without sleeves. +1.5 -1.5 Alignment of holding down bolts with sleeves. +5 -5 Level of holding down bolt assemblies. +10 -10 Embedded parts (in any direction). +5 -5 Centers of pockets or holes with greatest lateral dimension not exceeding 150mm.

+10 -10

Variation in steps: Riser +1.5 -1.5 Tread +3.0 -3.0 Plumb 3mm for every meter subject to

maximum of 10 mm. 5.1.5.3 Acceptance Criteria

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The acceptance criteria of concrete shall be in accordance with Clause 16 of IS: 456. However, in exceptional circumstances, the Engineer / Purchaser may, at his discretion, accept a concrete of lower strength than that specified at reduced rates. The concrete shall be deemed to comply with the strength requirements if:

i) Every sample has a test strength not less than the characteristic value or

ii) The mean strength shall exceed the characteristic strength by a margin of 1.65

times the standards deviation expected from the batching plant. However, no standard deviation less than 3.5 N/mm2 shall be used as a basis for designing a mix.

5.1.5.4 Load Test

If any work is found unacceptable whereupon the Engineer / Purchaser require its removal and reconstruction, the Contractor may request that it should be load tested in accordance with the provision of Clause 17.6 of IS: 456 as given below:

i) The test load shall be equivalent to the sum of the characterstic dead load and 125

percent of the characterstic superimposed load for which the structure or element was designed. This load shall not be applied earlier than 28 days after the effective hardening of concrete. This test load shall be maintained for 24 hours and during the entire duration of the test, struts, strong enough to take the whole superimposed, dead and other loads shall be placed in position, leaving a small gap under the members.

ii) The maximum deflection shall be measured after the test load is in position for 24

hours. Thereafter, the test load shall be removed. iii) If 24 hours after the removal of the load, the structure does not show a recovery of

at least 75 percent of the deflection, registered as in (ii) above, the test shall be repeated after a lapse of 72 hours. The structure shall be considered to have failed to pass the test if the recovery after the second test is not at least 80 percent of the maximum deflection during the second test.

iv) If the maximum deflection in mm, shown during 24 hours under load, is less than

40L2 /D, where L is the effective span in meters and D is overall depth of the section in mm, it is not necessary for the recovery to be measured and the recovery provision of the above mentioned Clause 3.1.5.4 (iii) will not apply.

5.1.6 RATES AND MEASUREMENTS 5.1.6.1 Rates

i) The quoted rates shall include the cost of labour, materials, getting the Concrete mix design done at an approved laboratory and further trial mixes at site, mix, placed in position, vibrating, compacting, finishing, curing etc., including the extra period of curing which shall be required when PPC/PSC is used in place of OPC. This shall also include the cost of curing, using curing compound, whenever used.

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ii) No extra cost shall be payable if any bonding / joining compound is applied on the

concrete surface due to stoppage of concreting for reasons attributable to the contractor

iii) The quoted rates shall include for all working conditions including in or under

water, liquid, mud, in or under foul positions, under tides, snow and extreme weather conditions.

iv) The quoted rates shall include for all incidentals, rendering, smoothening with

Carborundum stone, testing, curing, rectification etc.

v) The quoted rates shall include for maintaining stability of structure during execution.

vi) Nothing extra shall be payable for the handling/mixing of extra cement on account

of any reason or pouring of second stage concrete.

vii) Nothing shall be payable to the Contractor on account of facilities and arrangement provided by him for conducting ultrasonic or other relevant tests to ascertain grade and quality, etc. of the concrete, if required. In case of any defects, the Contractor shall rectify the same at his own cost.


i) Actual volume of work as executed or as per drawings issued, whichever is less, shall be measured in cubic meters.

ii) No deductions shall be made for the following:

Opening up to 0.1 Sq.m.

Volume occupied by reinforcement, sleeves, anchor bolts and similar items.

Volume occupied by pipes, piles, conduits, sheathing, etc. not exceeding 100 sq.cm. each in cross sectional area

The concrete works, below and above ground level shall be measured separately, unless otherwise specified, in the schedule of items.

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SUB SECTION - II

REINFORCEMENT

3.2.0 5.2.1 INTENT

This Sub-Section of the specification deals with reinforcement for all reinforced concrete works and covers the requirement of materials, their properties, storage, handling, furnishing of bar bending schedules and the cleaning, bending, binding and placing of reinforcement with suitable cover blocks. This shall also include the supply of reinforcement, wherever required.


The Contractor shall prepare and furnish to the Engineer / Purchaser, bar bending schedules for all RCC works for his review and approval. No work shall commence without the approval of bar bending schedules by the Engineer / Purchaser in writing.

The Contractor shall have to obtain prior written approval from the Engineer / Purchaser, if he desires any adjustments in diameter or spacing of reinforcement. However, the Contractor shall modify the bar bending schedule, when a particular type and size of reinforcement would not be available, with the approval of the Engineer / Purchaser.

5.2.2.1 MATERIALS

All steel for reinforced concrete works shall be in accordance with Technical Specification for Properties, Storage and Handling of common Building Materials (Section-2), which shall be deemed to form the part of this specification.

Mild steel bars and hard drawn steel wire shall conform to Grade-1 (Fe-250) of IS: 432 (Part-1). All high strength deformed steel bars shall be thermo-mechanically treated Bars and shall conform to grade Fe 500D of IS: 1786. Hard drawn steel wire fabrics shall conform to IS: 1566.

All bars shall be thoroughly cleaned before being fabricated. Pitted and defective bars shall not be used.

5.2.3 CODES AND STANDARD

For applicable codes and standards, refer to Clause no. 3.0.3 of Section – 3 of this specification, in addition to the Codes and Standard mentioned at various places under this Sub-Section.

5.2.4 TECHNICAL REQUIREMENTS - INSTALLATION 5.2.4.1 BENDING AND PLACING

This shall generally conform to Clause 12 and Clause 26 of IS: 456

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5.2.4.2 Bending

i) Reinforcing bars, supplied bent or in coils, shall be straightened before these are cut to size. Straightening of bars shall be done in cold and without damaging the bars. This is to be considered as a part of reinforcement bending and fabrication work.

ii) Unless otherwise specified, reinforcing steel shall be bent in accordance with

procedure specified in IS: 2502 and/or as approved by the Engineer / Purchaser. Bends and shapes shall comply strictly with the dimensions shown on the approved bar bending schedules and they shall be rechecked by the Contractor before bending and he shall be entirely responsible for their correctness. Bars correctly bent, shall only be used. Unless specified otherwise or directed by the Engineer / Purchaser, the detailing of reinforcement shall be in accordance with IS: 5525 and SP: 34.

iii) No reinforcement shall be bent when in position in the work without the approval

of the Engineer / Purchaser, whether or not it is partially embedded concrete. Where reinforcement bars are bent aside, at construction joints and afterwards bent back into their original positions, care shall be taken to ensure that, at no time, the radius of the bend is less than 4 times the bar diameters for plain mild steel or 6 times the bar diameters for deformed bars. Care shall also be taken while bending back bars, to ensure that the concrete around the bar is not damaged.

iv) Welding of bars to obtain continuity shall not be allowed, particularly for cold

twisted bars, unless specifically approved by the Engineer / Purchaser. If welding is approved, the work shall be carried out as per IS: 2751 and IS: 9417, according to the best practice and as directed by the Engineer / Purchaser.

5.2.4.3 Placing in Position

i) All reinforcement shall be accurately fixed and maintained in position as shown on the drawings by such approved means as steel chairs, and / or concrete spacer blocks as per IS: 2502. Bars intended to be in contact at crossing points, shall be securely bound together at all such, joints by two numbers annealed steel wire of 0.9 mm to 1.6 mm size conforming to IS: 280 in such a manner that they do not slip over each other at the time of fixing & concreting. The tying of bars shall be in criss-cross manner.

ii) Binders shall tightly embrace the bars with which these are intended to be in

contact and shall be securely held. The vertical distance between successive layers of bars shall be maintained by provision of spacer bars. These shall be so spaced that the main bars do not sag perceptively between adjacent spacers.

Bundled bars shall be provided wherever shown on the drawing to facilitate concreting. Location of laps and development lengths shall be as indicated on the drawings.

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i) The placing of reinforcement shall be completed well in advance of concrete

pouring. Just prior to concrete pouring, the reinforcement shall be checked by the Engineer / Purchaser, for accuracy of bar diameters, placement and cleanliness. Necessary corrections as directed by the Engineer / Purchaser shall be carried out. Care shall be taken to ensure that projecting ends of ties and other embedded metal do not encroach into the concrete cover. Where concrete blocks are used for ensuring the cover and positioning of reinforcement, these shall be made of mortar 1:2 (1 cement: 2 sand) by volume and cured for at least seven days. The sizes and locations of the concrete blocks shall be approved by the Engineer / Purchaser. The 28 days crushing strength of cover blocks shall be at least equal to the specified strength of concrete in which the blocks will be embedded.

ii) Laps and anchorage length of reinforcing bars shall be in accordance with IS: 456,

unless otherwise specified. If the bars in a lap are not of the same diameter, the smaller diameter will guide the lap length. Laps shall be staggered as far as practicable and as directed by the Engineer / Purchaser and not more than 50% of bars shall be lapped at a particular section. Mechanical connections, for splicing reinforcement bars in congested locations may be used by the Contractor, only if approved by the Engineer / Purchaser. Reinforcement bars shall not be lapped unless the length required exceeds the maximum available lengths of bars at site.

5.2.4.4 Cover to Reinforcement

Minimum cover requirements shall be as per design drawings.

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Sample bent bars shall be checked to ensure that they conform to the bar bending schedules. Reinforcement in position shall be checked for proper positioning, and rigidity, cover, spacing of bars, placement of chairs and spacers, etc. Also it shall be checked that all bars at crossings are properly tied.

5.2.5.2 Tolerance

Tolerance in construction, unless otherwise specified or as approved by the Engineer / Purchaser shall be as follows:

Description of item / Structural element in mm. (Max). Permissible Deviation

Placing of reinforcement For effective depth 200 mm or less For effective depth more than 200 mm Cover to reinforcement

+10 -5

+15 -10

-5

Cutting of reinforcement When minimum length specified When maximum length specified When maximum or minimum length not specified

+75 -

- -50

+75 -25

Frequency of sampling, testing and acceptance criteria of reinforcement work shall be given in Table 1 in Clause 3.0.5 of Section 3.


i) The quoted rates shall include for welding, cover block, providing binding wire, separator pieces between two or more layers of reinforcement, required for keeping the steel in position, etc.

ii) No extra will be paid for transportation from stores, straightening of steel,

modification of already embedded reinforcement, if required, due to faulty, fabrication or placement.

iii) No extra shall be paid for preparing and getting approved bar bending schedules (including all revisions).

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i) Bar or any other type of reinforcement used like hard drawn steel wire fabric etc. for reinforced concrete shall be measured by weight in tonnes. The weight shall be arrived at by multiplying the actual or theoretical length measured along with standard hooks, cranks, bends, authorised laps, etc. whichever is less, by the sectional weights. Claims for payment for this item shall be submitted with supporting documents giving the schedule of bars with sketches. The sectional weight to be adopted shall be IS section weight. Nothing extra will be payable to the Contractor on account of difference in weight, if any, due to different methods adopted for issue and measurement.

ii) Standard hooks, cranks, bends, authorised laps, supports, hangers and chairs, which

are covered in approved bar bending schedule, shall be measured in tonnes.

iii) Rolling tolerance of reinforcement shall be considered for reconciliation purpose only and not for payment.

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SUB SECTION - III

FORMWORK AND STAGING 5.3.1 INTENT

This Sub-Section of the specification deals with the requirements for the supply, erection, dismantling of formwork and staging required for cast-in-situ concrete works including for making pockets/blockouts.


The Contractor shall supply, fabricate, erect and dismantle (after use) all formwork and staging those are required for all activities covered under the specifications. He shall prepare the scheme and submit along with the supporting calculations for approval of the Engineer / Purchaser.

5.3.2.1 MATERIALS

i) Materials and accessories for false work (form work) shall conform to Clause no. 6 of IS: 14687.

ii) Formwork shall compose of steel, best quality wood or non-absorbent type

plywood. Timber shall be free from significant knots and shall be of medium grain as far as possible and hard woods shall be used as caps and wedges under or over posts. Timber shall be well seasoned, resin-bonded, water repellent, free from sap, shakes, worm holes, warps or other surface defects and shall have smooth finish.

iii) Staging, unless specified otherwise, shall generally be of mild steel tubes, steel

beams and channels etc. or strong sal ballies 150 mm in diameter or above. Bamboo, small diameter ballies etc., shall not be used unless approved by the Engineer / Purchaser in specific cases.

5.3.2.2 Classification Of Formwork

A) Ordinary

This shall be used in places where ordinary surface finish is required and shall compose of steel and/or approved good quality seasoned wood. The contractor can also use plywood shuttering.

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B) Plywood

This shall be used in exposed surfaces as shown on drawings or as directed by the Engineer / Purchaser where a specially, good finish is required. Such surface shall be formed using approved brand of heavy quality water resists plywood to produce perfectly levelled, uniform and smooth surface. All formwork shall be formed using approved quality BWP type, compressed (densified) plywood with suitable overlay (film faced) and conforming to IS: 3513 Part-III and IS: 4990 to produce a perfectly levelled, uniform and smooth surface. Reuse of such forms may be permitted only after inspection and approval by the Engineer / Purchaser, for each such reuse. Any damage to film face shall be caused for rejection. The faces of plywood with suitable overlay shall be dense, smooth and without blisters and patch marks. It shall be of uniform colour. Film face shall have minimum 250 GSM (Grams / Sq.m) coating.

C) Formwork for shell roofs

For this item, the detailed design of formwork shall be submitted by the Contractor to the Engineer / Purchaser, well in advance, for his approval. Units of shell forms may be used repeatedly but prior approval shall be required for each repetition. Extra care shall be taken to keep correct levels and profiles.



5.3.4 TECHNICAL REQUIREMENTS – INSTALLATION & REMOVAL 5.3.4.1 INSTALLATION

i) Formwork shall conform to Clause 11 of IS: 456. Formwork shall consist of all materials required for forming the boxing to pour concrete, including steel/wood/plywood forms, ties, anchors, hangers, inserts, etc. Formwork shall be so constructed that vertical and horizontal adjustments can be made as required. The design and engineering of formwork including staging as well as its erection and dismantling shall be the responsibility of the Contractor.

ii) The staging shall be true and rigid and thoroughly braced in both directions as well

as cross braced, strutted and propped such that it will not deform unduly under weight of concrete and other loads due to men, equipment, etc. Vertical members or props should not be supported on an unpropped lower suspended floor or beam unless it is ensured by the Contractor that the lower floor or beam can safely carry the loads. No propping shall take place until the Engineer / Purchaser's approval has been given to the Contractor's scheme submitted along with supporting calculations.

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iii) The forms and staging shall be sufficiently strong to carry without undue

deformation, the dead weight of the concrete as a liquid, as well as anticipated working loads. Where the concrete is vibrated, the formwork shall be strong enough to withstand the effects of vibration, without appreciable deflection, bulging, distortion or loosening of its components. The joints in the formwork shall be sufficiently tight to prevent any leakage of mortar. The formwork shall be such as to ensure a smooth uniform surface free from honeycombs, air bubbles, bulges, fins and other blemishes. Any blemish or defect found on the surface of the concrete, must be brought to the notice of the Engineer / Purchaser immediately and rectified as directed by him.

iv) To achieve the desired rigidity, ample studs, braces, bolts, spacer blocks, wires,

clamps, ties, straps, shores, etc. shall be used to hold the form in proper position without undue distortion. These shall be approved by the Engineer / Purchaser but they must in no way impair the strength of concrete or leave stains or marks on the finished surface. Where there are chances of these fixtures being embedded, only mild steel or concrete of adequate strength shall be used. Bolts passing completely through liquid and / or earth retaining walls / slabs, basement walls etc., for the purpose of securing and aligning the formwork, shall not be permitted.

v) For exposed interior and exterior concrete surfaces of beams and columns, plywood or other approved forms thoroughly cleaned and tied together with approved corrosion resistant devices shall be used. Rigid care shall be exercised ensuring that all column forms are in plumb / true level, and thoroughly cross braced to keep them in position.

vi) Bevelled strips 25x25 mm shall be provided to form angles and in corners of

columns and beam boxes for chamfering of corners if shown on drawings or directed by the Engineer / Purchaser. Temporary openings for cleaning, inspection and for pouring concrete shall be provided at the base of vertical forms and at other places, where these are necessary and as may be directed by the Engineer / Purchaser. The temporary openings shall be so formed that they can be conveniently closed rigidly when required and must not leave any mark on the concrete.

vii) If it is so desired by the Engineer / Purchaser, the Contractor shall prepare and

submit, before commencement of the actual work, designs and drawings for formwork and staging and get them approved by the Engineer / Purchaser. Formwork shall be so designed and positioned that it can be removed without damage to concrete.

viii) The Contractor shall maintain necessary camber in centering for all floor slabs and

beams in all spanning directions, so as to offset the deflection and assume correct shape. The camber shall have the crown of not less than 8 mm for every 5 meters span unless otherwise shown on the drawings. For cantilever, camber at free end shall be 1 in 100.

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ix) The Contractor shall provide the shuttering for complete stretch of work up to expansion joints for the structures like shell, folded plate etc. and/or as directed by the Engineer / Purchaser.

5.3.4.2 CLEANING AND TREATMENT OF FORMS

i) All forms shall be thoroughly cleaned of old concrete, wood shavings, saw dust, dirt and dust sticking to them before these are fixed in position. All rubbish, loose concrete, chipping, shavings, saw dust etc. shall be scrupulously removed from the interior of the forms before concrete is poured. Wire brushes, brooms, compressed air jet and/or water jet etc. shall be kept handy for cleaning, if directed by the Engineer / Purchaser.

ii) Before formwork is placed in position, the form surfaces that will be in contact with concrete shall be treated with approved non-staining oil or composition which is insoluble in water and not injurious to concrete. Care shall be taken that the oil or composition does not come in contact with reinforcing steel or stain the concrete surfaces. Burnt oil shall not be allowed to be used especially where the concrete surface will require finishing and/or plaster.

5.3.4.3 REMOVAL OF FORMS

i) This shall generally conform to Clause 11.3 of IS: 456 and 9.5 of IS: 14687

ii) The Contractor shall begin the removal of formwork only after approval of the Engineer / Purchaser. He shall place on record the dates on which the concrete is placed in different parts of the work and the dates of the removal of formwork therefrom. This record shall be checked and countersigned by the Engineer / Purchaser. The Contractor shall be responsible for the safe removal of Formwork but the Engineer / Purchaser may delay the time of removal if he considers it necessary. Any work showing signs of damage through premature removal of formwork, shall be entirely removed and reconstructed by the Contractor at no extra cost to the Purchaser.

iii) The formwork shall be so designed and erected that the forms for slabs and the

sides of beams, columns and walls may be removed first, leaving the beam bottoms and their supports in position. Repropping of beams shall not be done except with the approval of the Engineer / Purchaser. Formwork for columns and walls at each stage of concreting shall be erected only up to the particular lift of construction. Wedges, spacer bolts, clamps or other suitable means shall be provided to allow accurate adjustment of the formwork and to allow it to be removed gradually without jerking the concrete.

iv) Forms of various types of structural components shall, under normal

circumstances, not be removed before the minimum periods specified in Clause. 11.3 of IS: 456, which shall also be subject to the approval of the Engineer / Purchaser. However, in any case formwork shall not be struck until the concrete has reached strength, at least twice that of the stress to which the concrete may be subjected to at the time of removal of forms.

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v) In normal circumstances and where ordinary Portland cement is used, forms may

generally be removed after the expiry of the following periods, according to Clause 11.3 of IS: 456 and 9.5 of IS: 14687.

w) Walls, columns and vertical faces of all structural

members as directed by the Engineer / Purchaser

1 to 2 days

x) Slabs (Props left under)

3 days

y) Beam soffit (props left under)

7 days

z) Removal of props under slabs

Spanning up to 4.5 m Spanning over 4.5 m

7 days 14 days

aa) Removal of props under Beams Spanning up to 6 m Spanning over 6 m

14 days 21 days

bb) Cantilever Slabs

14 days

vi) The number of props left under, their sizes and disposition shall be such as to be

able to safely carry the full dead load of the slab, beam or arch as the case may be together with any live load likely to occur during curing or further construction.

vii) Where the shape of the element is such that the formwork has re-entrant angles, the

formwork shall be removed as soon as possible after the concrete has set, to avoid shrinkage cracking occurring due to the restraint imposed.

viii) In case of cantilever slabs, the removal of forms shall begin from the outer edge

and proceed towards the support, where as in the case of slabs supported on two/ four sides, the removal of forms shall begin from center to supports.

ix) The formwork shall be so made as to produce a finished concrete, true to shape,

lines, plumb and to dimensions as shown on the drawings. The Engineer / Purchaser may call for finished work at any time to set standards of workmanship. Once approved, these will become the accepted Sample.

x) In case PPC/PSC is used instead of OPC, the removal of shuttering/support shall be

after 50% more time from that being applied for OPC, unless otherwise permitted by the Engineer / Purchaser. For concrete temperature above 40 °C, stripping time shall be increased.

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xi) In case of special structures, such as shells, folded plates, etc., the sequence of removal of forms shall be as per drawings or as directed by the Engineer / Purchaser.

5.3.4.4 REUSE OF FORMS

Before reuse, all forms shall be thoroughly scraped, cleaned, all nails and adhering substances removed, holes and leaks satisfactorily plugged, joints examined and where necessary repaired and inside surfaces treated as specified herein before. Formwork shall not be used/re-used, if declared unfit or unserviceable by the Engineer / Purchaser.


Staging shall be checked for its soundness as a whole and for adequacy of the joints and its foundations. Formwork joints shall be inspected for soundness of connections. All joints shall be either vertical or horizontal and shall be such as to avoid loss of liquid through the formwork.

Dimensional Tolerance for Formwork (For Major Concrete Members like Foundation Mat, Slab etc.)

Levels and heights 6mm

Plumb 3mm for every meter subject to a maximum of 10mm.

Unevenness of any surface 3mm

Length / Breadth 12mm

Diagonals 15mm

Dimensional tolerance of framing members such as Beam, Column, Walls etc. shall be within +6 mm.

In case of inclined surfaces like track hopper wall, folded plates etc., the deviation in the alignment of inclined surfaces, shall not exceed 3 mm with reference to the theoretical alignment, for a length of 1000 mm measured vertically, subject to a maximum of 10 mm.

In addition to above, requirement of Clause 11.3 of IS: 456 shall be complied with, which shall be the final acceptance criteria of concrete work.

Frequency of sampling and testing of work, shall be as given in Table 1 in Clause 3.0.5 of Section 3.

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i) The quoted rates shall be inclusive of all staging, scaffolding, application of shuttering oil on surface, making the formwork water tight, etc.

ii) No separate payment shall be made for providing fillets, for rounding or

chamfering at junctions, corners, etc.

iii) The quoted rates shall include the cost of labour, materials etc., required for the extra time which shall be required for the removal of shuttering/support, when PPC/PSC is used in place of OPC.

iv) No extra payment shall be made on account of difficulty, wastage etc. for

placement/removal of formwork between the network of closely placed steel beams or for the lacing/bracing portions and ribbed slab constructions.

v) No extra cost shall be payable for providing Cribs & Girders for TG deck staging.


i) Formwork for different classes (types) shall be measured separately as the actual surface in contact with- the concrete and paid on area basis unless included in the rate for concrete. The unit of measurement shall be in Sq.m.

ii) Openings up to 0.1 Sq.m or boxing left for inserts etc. for facility of Contractor's

work, shall be neglected as if non-existent for the purpose of formwork measurement of surface in which the openings occur.

For suspended floor, no deduction shall be made for flange area of secondary steel beams.

iii) No measurement shall be taken for the formwork in pockets, openings, chases,

blockouts, etc. in concrete, if the surface area (cross-sectional area) is less than or equal to 0.1 Sq.m. in each case. If the cross-sectional area of any opening exceeds 0.1 Sq.m, the formwork shall be measured under appropriate classification of blockouts (form for a pocket or aperture in concrete).

iv) Formwork, if required, for joints shown on drawing or instructed by the Engineer /

Purchaser, shall be paid for the 'leading side' only.

v) Formwork for folded plate, shell and waffle slab roof shall be measured separately.

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SUB SECTION - IV

EMBEDDED PARTS

3.4.0 5.4.1 INTENT

This Sub-Section of specification deals with the supply, fabrication (where called for) and/or erection of embedded steel parts and PVC pipes including laying of rails and anchor fasteners.


i) Embedded steel parts shall be either furnished by the Purchaser for transportation & erection by the Contractor or supplied, fabricated and erected by the Contractor as stipulated. If supplied by the Purchaser, these parts shall be furnished anywhere within the project area and the Contractor shall transport and install the same in the work site.

ii) Embedded steel parts supplied by Purchaser and erected by the Contractor shall

include items such as, but not limited to, foundation grillages, anchor bolts, pipe sleeves, equipment mounting-plates, steel pieces properly welded with necessary lugs, as shown on the drawings, auxiliary framing for equipment supports, peg stay plugs for door and window frames, dowel bars for concrete work, miscellaneous frames, etc.

iii) Embedded steel parts supplied, fabricated/erected by the Contractor shall include

items such as, but not limited to plate inserts, edge protection angles, rolled sections with or without properly welded lugs. etc.

iv) Cold work deformed steel bars shall not be used for lugs.

5.4.2.1 MATERIALS

The materials shall be in accordance with the relevant clauses of Technical Specification for 'Properties, Storage and Handling of Common Building Materials (Section 2), which shall be deemed to form a part of this specification.

Mild steel pipes shall conform to IS: 1161. Unless otherwise specified, medium class pipes shall be provided. PVC pipes shall conform to IS: 4985. Minimum pressure rating shall be 2Kgf/ cm2

Rolled steel and structural steel shall conform to IS: 2062.


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5.4.4 TECHNICAL REQUIREMENTS - INSTALLATION

i) The Contractor shall fabricate, transport to site and erect accurately in position all embedded steel parts either by welding, bolting or any other means as approved by the Engineer / Purchaser. Exposed surfaces of embedded parts other than holding down bolts, unless otherwise stated, are to be painted with two coats ofprimer . The threads of holding down bolts shall be greased and protected with waterproof tape.

ii) During erection, the Contractor shall provide necessary strong temporary bracing

and supports to ensure proper installation of the embedded parts which shall be erected at the true location as shown on the drawings and these shall be in plumb and level (unless otherwise shown on drawings). The Contractor shall furnish the Engineer / Purchaser with fabrication and assembly drawings prepared for embedded steel parts showing the erection procedure, for major items, wherever necessary.

iii) Fabrication & erection shall be carried out as per IS: 800. Welding rods & site/

field welding shall conform to IS: 816 and IS: 9595. IS: 7634 (part-III) shall be followed for PVC pipe works.

5.4.4.1 Railway Track

Rail tracks, as directed by the Engineer / Purchaser, Shall be erected by the Contractor under supervision of a specialized agency appointed by owner. It shall be ensured by the contractor that the rails are installed true to line, level and gauge. The rail along with the fish plates, wherever required, shall be supplied by the owner.

5.4.4.2 Laying of rail

Laying of rail using rails of 52 kg/m (minimum) in Transformer yard, as per the direction of the Engineer / Purchaser or as shown in the drawings.

5.4.4.3 Anchor Fasteners

i) Expansion fasteners shall be used for fixing of steel members, embedments, equipment mounting frames and similar other parts subsequent to concrete work. Fasteners shall be of appropriate type, size and capacity as per manufacturer’s specification, and shall be installed by drilling holes of appropriate size in the concrete.

ii) All anchors shall be from established and approved manufacturers. Capacity of

anchor fasteners shall be as per manufacturer’s standards.

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iii) Anchors shall be fixed in position as recommended by the manufacturer and as approved by the Engineer / Purchaser.

iv) Anchor fasteners can be of mechanical bonding such as keying, friction, combined

friction – Keying or chemical bonding.

v) Capacity of the anchors shall be established after considering the effect of concrete grade, embedded depth, concrete thickness, anchor spacing and edge distance from the concrete edge.

vi) The selection for the particular type of bonding for the anchors shall be made after

considering the concrete grade, available embedment depth, load to be transferred, space available for installing anchors.

vii) Bonding of anchors can be either mechanical and / or chemical

The mechanical bonding anchors are torque controlled anchors made from carbon steel of grade 8.8 as per IS: 1367 Part III. Anchors in bolt as well as nuts version are acceptable. The bolt version anchors consists of bolt, washer, sleeves, plastic section, expansion sleeves and a cone. Nuts version anchors consist of nuts, threaded rod, washer, sleeve, plastic section, expansion sleeve and a cone. All steel components of anchors shall be electro galvanized to minimum 5 micron coating thickness. The plastic section shall be of Polyacetal Derlin 100 or equivalent.

Chemical bonding anchors shall consist of foil capsule and threaded rod. The

foil capsule shall contain the resin and hardener. The threaded rod shall have chiseled tip. The anchors shall be tested for its behaviour under fire as per heating curve ISO: 834 for up to 120 minutes and furnish the test result. Anchors of size M* to M24 shall conform to grade 5.8 and M27 to M39 anchors shall conform to 8.8 grade. The grades are as per IS: 1367 Part – III. All steel components of the anchors shall be electro galvanized to minimum 5 micron coating thickness.

viii) These anchors shall comprise of studs, nuts, washers and expansion sleeves. The

one end of the stud shall have thread and the other end shall have cold formed conical head. All steel components of the anchors shall be electro galvanized to minimum 5 micron coating thickness. The expansion sleeve shall preferably be of stainless steel of SS316. The anchors shall conform to minimum grade of 5.8 as per IS: 1367.

5.4.5 SAMPLING, TESTING AND QUALITY ASSURANCE

Frequency of sampling, testing and acceptance criteria shall be as per Table 1 in Clause no. 3.0.5 of Section 3.

5.4.6 RATES AND MEASUREMENTS

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5.4.6.1 Rates

i) The quoted rate shall include cutting, welding, fabrication, erection, embedding, painting, protective tape and transportation to site.

ii) Quoted rate shall also include the cost of materials, not issued by the Purchaser as

per relevant schedule of Item. 5.4.6.2 Measurements

iii) The measurement of this item shall be based on the calculated weight of steel installed in tonne corrected to second place of decimal. For mild steel and PVC pipes, measurements shall be in quintals. The lugs shall be measured in Kg.

v) Embedment of steel sections, M.S. pipes and PVC pipe work, shall be measured

separately.

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ANNEXURE – III: BID DRAWING

Sl. No.

Drawing Title Drawing Number

1 Layout and Details of Ash Pond Divide Bund (Part-II)

-

Note: The Contractor’s scope of work shall include all works required for the construction of Ash Pond Divide Bund as covered in scope of work specification and the approved construction drawings.

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TSPL ASH POND

BOUNDARY LINE OF

LIMITS OF D/S TOE OF STARTER DYKE

LIMITS OF U/S TOE OF STARTER DYKE

WALL

BOUNDARY

E=27239.704

N=45940.085

E=27245.553

N=45938.555ANY ASH ZONE

WITH EARTH WITHOUT

BUND CONSTRUCTED

E=27750.082

N=45828.541

E=27755.877

N=45832.429E=26645.364

N=46065.571

E=26639.494

N=46071.890

COMPARTMENT ACOMPARTMENT B

STARTER DYKE

U/S TOE OF

STARTER DYKE

D/S TOE OF

E=26778.567

N=45109.739

E=26774.435

N=45104.236

E=27704.955

N=45581.931

E=27704.375

N=45385.724E=26987.840

N=45310.285

E=272.93.682

N=45339.469

E 27730.863

N 45215.380

E=27736.632

N=45210.819

PIPE

DECANTATION

RL. 220.100

TOP OF STARTER DYKE

CLARIFIER POND

E=27134.236

N=45150.095

E=27140.384

N=45150.805

UPTO RL.216.35

ASH ZONE FILLED

UPTO RL.215.45

ASH ZONE FILLED

UPTO RL.214.75

ASH ZONE FILLED

FOR BID PURPOSE ONLY

METRE UNO.

ALL DIMENSIONS ARE IN MM, ELEVATIONS AND CO-ORDINATES ARE IN01.

02.

01.

PRA-TSPL-1225-C-DWG-003 SHEET 01 OF 03 RECEIVED FROM TSPL.

CO-ORDINATES ARE GIVEN IN REFERENCE OF DETAILED DRAWING NO.

CONTRACT CONDITIONS.

ALL WORKS SHALL BE CARRIED OUT AS PER TECHNICAL SPECIFICATIONS AND

LAYOUT OF ASH POND DIVIDE BUND

E=27166.095

N=45343.386

E=27160.239

N=45344.864

E=27205.795

N=45686.093

E=27211.651

N=45684.615

A

BB

CC

DIVIDE BUND

ASH POND

WELL

DECANTATION

N

NOTES:

SPECIAL NOTES:

PROJECT:3X660 MW THERMAL POWER PLANT

TALWANDI SABO POWER LIMITED, MANSA, PUNJAB

TITLE:LAYOUT AND DETAILS OF ASH POND DIVIDE BUND

(SHEET 1 OF 2)

134 of 144

65

00

5500

75

00

1500

3000

3000

1500

6000

1000

1500

3000

3000

15

00

6000

6000

6000

1500

6000

3000

3000

15

00

6000

1000

1000

HDPE MEMBRANE

0.6 MM THK

(FLY ASH BRICKS)

BRICK ON EDGE PITCHING

1

31

3

COVER ALL AROUND

1000 THK EARTH

NGL

CORE

CLAY

BRICK MASONRY

300 THK

(250 MM)

STONE RIP RAP

ANCHOR TRENCH

500 X 500LAYER (12-40)

300 THK AGGREGATE

NGL

COVER

EARTH

@ 5M C/C

BLANKET DRAIN

500 THK.

FLYASH ZONE

FLYASH ZONEFLYASH ZONE

SECTION A(HEIGHT 4 TO 5M)

GEOTEXTILE

HDPE MEMBRANE

0.6 MM THK

(FLY ASH BRICKS)


1

3

COVER ALL AROUND

1000 THK EARTH

1

3

CORE

CLAY

NGL

BRICK MASONRY

300 THK COVER

EARTH

NGL

FLYASH ZONE

FLYASH ZONE FLYASH ZONE

@ 5M C/C

BLANKET DRAIN

500 THK.LAYER (12-40)

300 THK AGGREGATE

GEOTEXTILE

SECTION B(HEIGHT 5 TO 6.5M)

ROADCL

WITH BRICKS

TRENCH FILLED

500 X 500 ANCHOR

WITH BRICKS

TRENCH FILLED

500 X 500 ANCHOR

SECTION C(HEIGHT 7.5 TO 8M)

WITH BRICKS

TRENCH FILLED

500 X 500 ANCHOR

HDPE MEMBRANE

0.6 MM THK

(FLY ASH BRICKS)


1

3

COVER ALL AROUND

1000 THK EARTH

NGL

ANCHOR TRENCH

500 X 500

FLYASH ZONE

FLYASH ZONE

FLYASH ZONE

1000 THK EARTH LAYER 1000 THK EARTH LAYER

1

3

BRICK MASONRY

300 THK

LAYER (12-40)

300 THK AGGREGATE

GEOTEXTILE

NGL

CORE

CLAY

COVER

EARTH

COVER

EARTH

RL. 220.5 M

RL. 220.5 M

RL. 220.5 M

ANCHOR TRENCH

500 X 500

ROADCL

ROADCL

CHIMNEY DRAIN

500 THK.

CHIMNEY DRAIN

500 THK.

CHIMNEY DRAIN

500 THK.

500 THK EARTH COVER 500 THK EARTH COVER

500 THK EARTH COVER 500 THK EARTH COVER

PROJECT:3X660 MW THERMAL POWER PLANT

TALWANDI SABO POWER LIMITED, MANSA, PUNJAB

TITLE:

FOR BID PURPOSE ONLY

NOTES:

SPECIAL NOTES:

METRE UNO.

ALL DIMENSIONS ARE IN MM, ELEVATIONS AND CO-ORDINATES ARE IN01.

02.

01.

PRA-TSPL-1225-C-DWG-003 SHEET 01 OF 03 RECEIVED FROM TSPL.

CO-ORDINATES ARE GIVEN IN REFERENCE OF DETAILED DRAWING NO.

AND CONTRACT CONDITIONS.

ALL WORKS SHALL BE CARRIED OUT AS PER TECHNICAL SPECIFICATIONS

LAYOUT AND DETAILS OF ASH POND DIVIDE BUND

(SHEET 2 OF 2)

(SHEET 1)

(SHEET 1)

(SHEET 1)

COMPARTMENT B COMPARTMENT A



135 of 144

Section xx





Date: 12.DEC.2017


ANNEXURE – IV: SCHEDULE OF PARTICULARS (BY BIDDER)

Schedule 1 : Schedule of General Particulars of Bidder Schedule 2 : Schedule of Experience list of Bidder Schedule 3 : Schedule of documents to be submitted with the bid Schedule 4 : Schedule of documents to be submitted after the award of contract Schedule 5 : Schedule of Deviations from Technical Specification

136 of 144

Section xx





Date: 12.DEC.2017


SCHEDULE– 1: SCHEDULE OF GENERAL PARTICULARS OF THE BIDDER

Sl. No. Description Details to be filled by Bidder 1 Name of Bidder with registered office address

2 Telephone No. 3 Fax No. 4 E – Mail 5 Name and Designation of the Official of the

Bidder to whom all reference shall be made

6 Financial Details Enclose copies of Audited Balance sheet and Profit and Loss Account for past three (3) years.

Yes / No

7 Indicate following for the past three (3) years with projection for next three (3) years. i) Annual turnover: ii) Annual profit:

8 Name and Address of the Bankers to the Company

9 Project organisation chart showing staffing, furnished

Yes / No

10 List of important personnel with brief curriculum vitae, furnished

Yes / No

137 of 144

Section xx





Date: 12.DEC.2017


SCHEDULE– 2: SCHEDULE OF EXPERIENCE LIST OF BIDDER

The Bidder shall furnish a list of similar jobs executed by him to whom reference may be made by the Owner in case the Owner considers such a reference is necessary.

Sl. No. Name & Description of contract

Value of Contract

Order date & number

Contract execution duration

Contact Person

138 of 144

Section xx





Date: 12.DEC.2017


SCHEDULE– 3: SCHEDULE OF DOCUMENTS TO BE SUBMITTED ALONG WITH BID

The Bidder shall list the drawings/documents submitted along with the bid in line with the requirements.

Sl. No. Drawing/ Document No. of Copies Remarks

139 of 144

Section xx





Date: 12.DEC.2017


SCHEDULE– 4: SCHEDULE OF DOCUMENTS TO BE SUBMITTED AFTER AWARD OF CONTRACT

The Bidder shall list the drawings/documents to be submitted after award of Contract including the scheduled date of submission and their category of approval. The drawings/documents to be submitted shall be in line with the requirements specified in Technical Requirement portion of the specification. This schedule will be subject to Owner’s approval before placement of order.

S. No. Drawing/ Document No. of Copies

Duration after award of Contract

Category Remarks

140 of 144

Section xx





Date: 12.DEC.2017


SCHEDULE– 5: SCHEDULE OF DEVIATIONS FROM TECHNICAL SPECIFICATIONS

All deviations from the Technical Specification shall be filled in by the Bidder clause by clause in this schedule. S. No. Section &

Clause no. Deviation Taken Reason for Deviation

The Bidder hereby certifies that the above mentioned are the only deviations from the Specifications of this inquiry.

Signature & Seal of the Bidder

141 of 144

Section xx





Date: 12.DEC.2017


ANNEXURE – V: SUB SOIL DATA

142 of 144

143 of 144

144 of 144

Documents

SCHEDULE OF ITEMS - ASH POND DIVIDE BUND Sl No. Rate ... · SCHEDULE OF ITEMS - ASH POND DIVIDE BUND Sl No. Rate Amount (Rs) (Rs) I-1 EXCAVATION AND FILLING 1. ... Ordinary formwork